CN118572948B

CN118572948B - Comprehensive heat dissipation system and axial flux motor

Info

Publication number: CN118572948B
Application number: CN202411053121.2A
Authority: CN
Inventors: 张培圣; 徐蕾
Original assignee: Guangneng Yineng Beijing Nuclear Energy Technology Co ltd
Current assignee: Guangneng Yineng Beijing Nuclear Energy Technology Co ltd
Priority date: 2024-08-02
Filing date: 2024-08-02
Publication date: 2024-10-18
Anticipated expiration: 2044-08-02
Also published as: CN118572948A

Abstract

The invention relates to the technical field of axial flux motors, in particular to a comprehensive heat dissipation system and an axial flux motor, and aims to solve the problem that an existing motor can only cool a rotor. The comprehensive heat dissipation system provided by the invention comprises a motor main shaft, a motor shell, a rotor unit and a stator unit; and forms a circulating air passage which is formed by sequentially connecting a radial air passage, a communicating air passage, a backflow air passage, a return air hole, a main shaft inner cavity and an air outlet hole; and a cooling channel consisting of the first annular flow channel, the second annular flow channel and the radial flow channel. The comprehensive heat dissipation system provided by the invention enhances the cooling effect of the inside of the motor shell through the mutual matching of the circulating air passage and the cooling channel, namely, the circulating air passage uniformly distributes heat, so that the air running in the circulating air passage is cooled by means of the cooling channel, the condition that the motor can only cool the rotor is avoided, and the motor performance and stable operation are ensured.

Description

Comprehensive heat dissipation system and axial flux motor

Technical Field

The invention relates to the technical field of axial flux motors, in particular to a comprehensive heat dissipation system and an axial flux motor.

Background

The existing axial flux motor generally cools a rotor in a liquid cooling mode due to the explosion-proof performance requirement, but other parts except the rotor in the motor can generate heat and cause temperature rise due to factors such as friction, eddy loss and hysteresis, so that the performance of the motor is influenced and the motor runs stably.

Disclosure of Invention

The invention aims to provide a comprehensive heat dissipation system and an axial flux motor so as to solve the problem that the existing motor can only cool a rotor.

In order to solve the technical problems, the technical scheme provided by the invention is as follows:

A comprehensive heat dissipation system comprises a motor main shaft, a motor shell, a rotor unit and a stator unit; the motor main shaft is rotatably arranged in the motor shell, and the rotor unit and the stator unit are sleeved on the motor main shaft and are arranged in the motor shell;

one side of the rotor unit is provided with a radial air passage, the other side of the rotor unit and the motor shell enclose a backflow air passage, and the outer circle of the rotor unit and the motor shell enclose a communication air passage; the motor spindle is provided with a spindle cavity, and a return air hole and an air outlet hole which are communicated with the spindle cavity;

The radial air passage, the communication air passage, the backflow air passage, the return air hole, the main shaft inner cavity and the air outlet hole are sequentially communicated to form a circulation air passage;

a first annular flow passage, a second annular flow passage and a radial flow passage are arranged in the stator unit; one end of the radial flow channel is communicated with the first annular flow channel, and the other end of the radial flow channel is communicated with the second annular flow channel; the first annular flow passage, the second annular flow passage and the radial flow passage form a cooling passage.

Further, the rotor unit comprises a plurality of permanent magnets uniformly distributed around the axis of the rotor unit, and gaps between adjacent permanent magnets form the radial air passage.

Further, the rotor unit further comprises a main back iron and a limiting cover plate; the permanent magnet is arranged on the main back iron, and a limiting hole is formed in the limiting cover plate; the permanent magnet is inserted into the limiting hole, and one end of the permanent magnet protruding out of the limiting cover plate and the limiting cover plate enclose the radial air passage.

Further, the motor spindle comprises an output shaft and a shaft sleeve, wherein the shaft sleeve is sleeved on the output shaft and surrounds an annular spindle inner cavity with the output shaft;

The shaft sleeve is provided with the air outlet.

Further, the motor main shaft further comprises shaft covers, and the two shaft covers are sleeved on the output shaft and connected with the output shaft; the two shaft end covers are inserted into the shaft sleeve and enclose the main shaft inner cavity together with the shaft sleeve and the output shaft; the shaft end cover is provided with the return air hole.

Further, the stator unit comprises a stator shell and stator windings, and a plurality of stator windings are annularly arranged in the stator shell; the stator shell comprises an upper positioning cover plate, a lower positioning cover plate, an inner circular ring and an outer circular ring;

the inner ring is inserted into the outer ring and is coaxially arranged with the outer ring; the upper positioning cover plate and the lower positioning cover plate are respectively connected with two ends of the inner circular ring and two ends of the outer circular ring;

The upper positioning cover plate and the lower positioning cover plate are respectively abutted to two ends of the stator winding;

The outer ring, the upper positioning cover plate, the lower positioning cover plate and the stator winding form a first annular flow passage; the inner ring, the upper positioning cover plate, the lower positioning cover plate and the stator winding form a second annular flow passage; the upper positioning cover plate, the lower positioning cover plate and the stator winding enclose a radial flow channel.

Further, the outer ring is provided with cooling ports, and the two cooling ports are uniformly distributed around the axis of the outer ring and are communicated with the first annular flow passage.

Further, rib plates are arranged on one sides, close to each other, of the upper positioning cover plate and the lower positioning cover plate, and extend along the radial direction of the upper positioning cover plate; the rib plate of the lower positioning cover plate extends along the radial direction of the lower positioning cover plate;

the upper positioning cover plate and the lower positioning cover plate are respectively provided with a positioning groove, and the rib plates are arranged between two adjacent positioning grooves;

the stator winding comprises a stator core and a coil winding sleeved on the stator core;

The two ends of the stator core are respectively abutted against the positioning grooves of the upper positioning cover plate and the lower positioning cover plate;

The coil winding is arranged between two adjacent rib plates and is in contact with the rib plates.

Further, the upper positioning cover plate is connected with the inner ring and the outer ring by adopting screws, and the joint is sealed by using sealant;

the lower positioning cover plate is integrally injection molded with the inner ring and the outer ring or connected by adopting screws, and the joint is sealed by using sealant.

In another aspect of the present invention, an axial flux electric machine is provided, comprising the above-described integrated heat dissipation system.

In summary, the technical effects achieved by the invention are as follows:

The comprehensive heat dissipation system provided by the invention comprises a motor main shaft, a motor shell, a rotor unit and a stator unit; the motor main shaft is rotatably arranged in the motor shell, and the rotor unit and the stator unit are sleeved on the motor main shaft and are arranged in the motor shell; one side of the rotor unit is provided with a radial air passage, the other side of the rotor unit and the motor shell enclose a backflow air passage, and the excircle of the rotor unit and the motor shell enclose a communication air passage; a main shaft cavity and an air return hole and an air outlet hole which are communicated with the main shaft cavity are formed in the main shaft of the motor; the radial air passage, the communication air passage, the backflow air passage, the return air hole, the main shaft inner cavity and the air outlet hole are sequentially communicated to form a circulation air passage; the stator unit is internally provided with a first annular flow passage, a second annular flow passage and a radial flow passage; one end of the radial flow channel is communicated with the first annular flow channel, and the other end of the radial flow channel is communicated with the second annular flow channel; the first annular flow passage, the second annular flow passage and the radial flow passage form a cooling passage.

In the integrated heat radiation system provided by the invention, the cooling channel is used for realizing the cooling of the stator unit, and cooling medium can be introduced and circulated through the circulating pump; the circulating air passage is used for realizing air circulation in the motor shell so as to uniformly distribute heat and avoid excessive heating of parts caused by local heat aggregation. The cooling effect to the inside of motor casing can be strengthened to the mutually supporting of circulation air flue and cooling channel, and circulation air flue makes heat evenly distributed promptly to cool off the gaseous of operation in the circulation air flue with the help of cooling channel, avoided the motor can only cool off the condition to the rotor, avoid other parts to gather because of the heat that factors such as friction, vortex loss, hysteresis lag produced, thereby guarantee motor performance and steady operation. If no circulating air passage exists, the cooling effect generated by the cooling passage can only cool the air near the stator unit, and the cooling of the inside of the whole motor shell can not be realized.

Drawings

In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are needed in the description of the embodiments or the prior art will be briefly described, and it is obvious that the drawings in the description below are some embodiments of the present invention, and other drawings can be obtained according to the drawings without inventive effort for a person skilled in the art.

Fig. 1 is a schematic structural diagram of a comprehensive heat dissipation system according to an embodiment of the present invention;

FIG. 2 is an enlarged view of FIG. 1 at A;

fig. 3 is a schematic structural diagram of an axial flux motor according to an embodiment of the present invention;

FIG. 4 is a schematic diagram of the motor spindle;

FIG. 5 is a front view of the motor spindle;

FIG. 6 is a cross-sectional view B-B of FIG. 5;

FIG. 7 is a schematic structural view of a rotor unit;

FIG. 8 is a cross-sectional view at C in FIG. 7;

FIG. 9 is a schematic structural view of a primary back iron;

fig. 10 is a front view of the electrode housing;

FIG. 11 is a sectional view D-D of FIG. 10;

fig. 12 is a schematic structural view of a stator unit;

Fig. 13 is a front view of the stator unit;

FIG. 14 is a sectional view E-E of FIG. 13;

fig. 15 is a partial enlarged view of F in fig. 14;

FIG. 16 is a schematic view of the structure of the upper positioning cover plate;

FIG. 17 is a front view of the upper positioning cover plate;

fig. 18 is an enlarged view of G in fig. 17;

FIG. 19 is a schematic view of the inner ring;

FIG. 20 is a schematic view of the structure of an outer ring;

FIG. 21 is a schematic structural view of a stator winding;

fig. 22 is a schematic structural view of a stator core.

Icon: 100-a motor spindle; 200-a motor housing; 300-rotor unit; 400-stator unit; 110-an output shaft; 120-shaft sleeve; 130-shaft end caps; 310-permanent magnet; 320-main back iron; 330-a limit cover plate; 340-auxiliary back iron; 311-an annular mounting groove; 410-a stator housing; 420-stator windings; 411-upper positioning cover plate; 412-lower positioning cover plate; 413-an inner ring; 414-an outer ring; 415-a lead tube; 401-rib plates; 402-positioning grooves; 403-cylindrical boss; 404-a first threaded hole; 405-limiting clamping grooves; 406-rectangular boss; 407-a second threaded hole; 408-a third threaded hole; 421-stator core; 422-coil windings; 101-radial airway; 102-connecting the air passage; 103-return airway; 104-a return air hole; 105-spindle cavity; 106-an air outlet hole; 201-a first annular flow channel; 202-a second annular flow passage; 203-radial flow channels; 204-cooling ports.

Detailed Description

For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent that the described embodiments are some embodiments of the present invention, but not all embodiments of the present invention. The components of the embodiments of the present invention generally described and illustrated in the figures herein may be arranged and designed in a wide variety of different configurations.

Thus, the following detailed description of the embodiments of the invention, as presented in the figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of selected embodiments of the invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.

Some embodiments of the present invention are described in detail below with reference to the accompanying drawings. The following embodiments and features of the embodiments may be combined with each other without conflict.

In view of this, the present invention provides an integrated heat dissipation system including a motor main shaft 100, a motor housing 200, a rotor unit 300, and a stator unit 400; the motor main shaft 100 is rotatably installed in the motor housing 200, and the rotor unit 300 and the stator unit 400 are sleeved on the motor main shaft 100 and are arranged in the motor housing 200; one side of the rotor unit 300 is provided with a radial air passage 101, the other side of the rotor unit and the motor shell 200 enclose a backflow air passage 103, and the outer circle of the rotor unit 300 and the motor shell 200 enclose a communication air passage 102; the motor spindle 100 is provided with a spindle cavity 105, a return air hole 104 and an air outlet hole 106 which are communicated with the spindle cavity 105; the radial air passage 101, the communication air passage 102, the backflow air passage 103, the return air hole 104, the main shaft inner cavity 105 and the air outlet hole 106 are sequentially communicated to form a circulating air passage; the stator unit 400 is provided with a first annular flow passage 201, a second annular flow passage 202 and a radial flow passage 203; one end of the radial flow channel 203 is communicated with the first annular flow channel 201, and the other end is communicated with the second annular flow channel 202; the first annular flow passage 201, the second annular flow passage 202 and the radial flow passage 203 constitute a cooling passage.

In the integrated heat dissipation system provided by the invention, the cooling channel is used for realizing the cooling of the stator unit 400, and a cooling medium can be introduced and circulated through the circulating pump; the circulation air channel is used for realizing air circulation in the motor shell 200 so as to uniformly distribute heat and avoid excessive heating of parts caused by local heat accumulation. The cooling effect to the inside of motor housing 200 can be strengthened to the mutually supporting of circulation air flue and cooling channel, and circulation air flue makes heat evenly distributed promptly to cool off the gas of operation in the circulation air flue with the help of cooling channel, avoided the motor can only cool off the condition of rotor, avoid other parts to gather because of the heat that factors such as friction, vortex loss, hysteresis lag produced, thereby guarantee motor performance and steady operation. If there is no circulating air passage, the cooling effect generated by the cooling passage can only cool the air near the stator unit 400, and the cooling of the inside of the whole motor housing 200 cannot be realized.

The structure and shape of the integrated heat dissipation system according to the present embodiment are described in detail below with reference to fig. 1 to 22:

in this embodiment, the integrated heat dissipation system includes a motor spindle 100, a motor housing 200, a rotor unit 300 and a stator unit 400, as shown in fig. 1, the motor spindle 100 is mounted on the motor housing 200 through a bearing, the stator unit 400 is mounted in the motor housing 200, and the two rotor units 300 are sleeved on the motor spindle 100 and are respectively disposed on two sides of the stator unit 400.

Specifically, one side of the rotor unit 300 is provided with a radial air passage 101, as shown in fig. 8, and the other side of the rotor unit and the motor housing 200 enclose a backflow air passage 103, as shown in fig. 2; the outer circle of the rotor unit 300 encloses a communication air passage 102 with the motor housing 200 as shown in fig. 2; the motor spindle 100 is provided with a spindle cavity 105, and a return air hole 104 and an air outlet hole 106 which are communicated with the spindle cavity 105, as shown in fig. 2 and 4. Radial air flue 101, communication air flue 102, backward flow air flue 103, return air hole 104, main shaft inner chamber 105 and air outlet hole 106 communicate in proper order in order to form the circulation air flue.

In this embodiment, two paths of relatively independent circulating air passages are formed, and the two paths of circulating air passages are respectively located at two sides of the stator unit 400.

When in operation, the rotor unit 300 drives the motor spindle 100 to rotate, and the gas in the radial air passage 101 is driven to rotate along with the rotor unit 300 along with the rotation of the rotor unit 300 around the axis thereof, so that centrifugal force is generated to enable the gas in the radial air passage 101 to flow to the outer circle of the rotor unit 300, namely to flow to the communication air passage 102. Meanwhile, as the gas in the radial air passage 101 flows out to generate negative pressure, the gas sequentially flows through the radial air passage 101, the communication air passage 102, the backflow air passage 103, the return air hole 104, the main shaft inner cavity 105 and the air outlet hole 106 under the drive of the pressure difference generated by the negative pressure and the centrifugal force to form internal circulating flow, so that heat is uniformly distributed, and heat aggregation is prevented.

In an alternative of this embodiment, the motor spindle 100 includes an output shaft 110, a sleeve 120, and a shaft cover 130, as shown in fig. 4 and 6. The shaft sleeve 120 is sleeved on the output shaft 110, the two shaft end covers 130 are sleeved on the output shaft 110 and connected with the output shaft 110, and the two shaft end covers 130 are inserted on the shaft sleeve 120 and form an annular main shaft inner cavity 105 together with the shaft sleeve 120 and the output shaft 110. The shaft sleeve 120 is provided with air outlet holes 106 uniformly distributed around the axis thereof, and the shaft end cover 130 is provided with air return holes 104 uniformly distributed around the axis thereof. The spindle cavity 105 may be a hole extending along the axial direction of the motor spindle 100, and two ends of the hole are respectively communicated with the air outlet hole 106 and the return air hole 104.

In this embodiment, the rotor unit 300 includes a permanent magnet 310, a main back iron 320, a limit cover plate 330, and a sub back iron 340, as shown in fig. 2 and 8. The main back iron 320 is provided with an annular mounting groove 311, as shown in fig. 9, the auxiliary back iron 340 and the permanent magnet 310 are both mounted in the annular mounting groove 311, and the auxiliary back iron 340 is disposed between the main back iron 320 and the permanent magnet 310, one side of which is connected with the main back iron 320, and the other side of which is connected with the permanent magnet 310. The plurality of permanent magnets 310 are uniformly distributed around the axis of the main back iron 320, and the limit cover plate 330 is arranged on one side of the auxiliary back iron 340 connected with the permanent magnets 310. The limiting cover plate 330 is provided with a limiting hole, the permanent magnet 310 is inserted into the limiting hole to ensure the position to be fixed, one end of the permanent magnet 310 protruding out of the limiting cover plate 330 and the limiting cover plate 330 enclose a radial air passage 101, namely, a radial air passage 101 is formed between the adjacent permanent magnet 310 and the limiting cover plate 330.

In this embodiment, the auxiliary back iron 340 is configured as an annular structure wound by a magnetic conductive plate, the annular structure is radially divided into multiple layers, and insulating glue is filled between the layers. The magnetic conductive plate is made of a material with ultrahigh magnetic permeability, and can be made of silicon steel material or nanocrystalline material, so that the auxiliary back iron 340 is ensured to have good magnetic conductivity and generation of vortex is inhibited; the insulating glue is a bi-component epoxy resin glue.

The rotor unit 300 provided in this embodiment ensures the supporting strength through the main back iron 320, and adopts the auxiliary back iron 340 formed by winding in multiple layers to conduct magnetic conduction on the permanent magnet 310, and reduces the eddy current loss and the harmonic loss through the multiple layers of the auxiliary back iron, so that the heating of the permanent magnet 310 is significantly reduced, and the situations of high motor loss and demagnetization of the permanent magnet 310 are avoided.

Specifically, the shape of the auxiliary back iron 340 is a vortex line, and coil springs, disc-type mosquito coils, etc. are provided in the same shape. Insulation between layers and fixation of the ring structure of the sub back iron 340 are achieved through the insulating glue, so that a compact lamellar structure is achieved to reduce eddy current loss and harmonic loss by reducing thickness, and meanwhile, resistance value can be increased to reduce induced current.

In this embodiment, the main back iron 320 may be made of steel, such as 45 # steel, so as to obtain good machining precision and supporting strength, and prevent bending deformation caused by the pulling force of the rotor on the permanent magnet 310. Through the combined use of the main back iron 320 and the auxiliary back iron 340, not only the supporting strength of the rotor unit 300 is ensured, but also the generation of vortex is effectively suppressed.

In this embodiment, the limiting cover plate 330 is made of a non-metal material such as glass fiber plate, carbon fiber reinforced plastic, glass fiber reinforced PEEK, etc., so as to ensure the limiting strength of the permanent magnet 310 and avoid generating induced current. As shown in fig. 8, the four corners of the limiting hole are provided with circular arcs, and sharp corners are removed by milling the circular holes, thereby facilitating the installation of the permanent magnet 310.

In an alternative of this embodiment, the permanent magnet 310 is divided into multiple layers along the radial direction of the secondary back iron 340, and insulating glue is filled between the layers. The permanent magnet 310 made of a multi-layer structure can reduce eddy current loss and harmonic loss. The insulating glue can also be a bi-component epoxy resin glue to achieve adhesion and insulation from layer to layer. Preferably, the number of layers of the permanent magnet 310 is the same as and corresponds to the number of layers of the auxiliary back iron 340 one by one, so as to avoid the condition that the insulating layer is disabled due to the mutual conduction of the permanent magnet and the auxiliary back iron. That is, it is avoided that two adjacent layers of the auxiliary back iron 340 are simultaneously connected with one layer of the permanent magnet 310, thereby leading to conduction of two adjacent layers of the auxiliary back iron 340.

In the alternative of this embodiment, the permanent magnet 310 is made of rare earth permanent magnet material, and due to the low internal resistance of the rare earth permanent magnet material, significant eddy current loss occurs when the motor operates. The multi-layer permanent magnet 310 composed of tens of permanent magnet sheets by adopting an insulating adhesive bonding mode can block the formation of eddy current to reduce loss and can reduce the temperature of the permanent magnet 310 to avoid high-temperature loss of magnetism.

In an alternative scheme of this embodiment, the permanent magnet 310 may be configured as a sector or a trapezoid, and by adjusting the shape, the rotation speed of the motor when resonance occurs is improved, so as to prevent the motor from shaking and resonance squeal noise in the working state, and keep the motor running stably. In this embodiment, the permanent magnet 310 is designed to resonate the motor at a rotational speed of 2000 rpm or higher, and at a rotational speed of 1500 rpm or lower. The various losses of the rotor unit 300 of this embodiment are reduced to a negligible extent, making the motor more energy efficient and power efficient, with a power saving rate of up to 30% -80%.

In this embodiment, the main back iron 320 is connected with the shaft cover 130 and the shaft sleeve 120 by screws at the same time to connect the rotor unit 300 with the motor spindle 100, and controls the interval between the two rotor units 300.

The existing axial flux motor is designed with very low power, and the diameter of the motor is increased after the power is increased, and the diameter of the rotor is correspondingly increased, so that the distance from the outer circle of the motor shaft to the inner circle formed by the permanent magnets 310 is larger, and the distance from the axis of the rotor to the permanent magnets 310 is larger. This situation can cause permanent magnets 310 to easily attract the stator core during assembly of the motor, resulting in bending and deformation of the back Railway Bureau portion of the rotor and difficulty in disassembly, and even if assembled, the air gap of the motor needs to be set larger. In this embodiment, the shaft sleeve 120 is provided to form the hollow shaft of the motor spindle 100, and increases the diameter of the motor spindle 100 where the rotor unit 300 is mounted, and shortens the distance between the permanent magnet 310 and the surface of the motor spindle 100, thereby reducing the moment arm when the permanent magnet 310 is under the tensile force of the stator unit 400, and avoiding the bending deformation of the main back iron 320 due to the overlarge bending moment. This structure has both guaranteed that the both ends of motor main shaft 100 use the minor diameter bearing to support, has shortened the arm of force of stator core actuation permanent magnet 310 again, has avoided main back iron 320 bending deformation to lead to the motor to damage, has avoided simultaneously again to increase back iron thickness alone and has led to the moment of inertia increase of rotor unit 300, reduces the problem of motor efficiency.

In short, the hollow stepped shaft of the present embodiment shortens the distance between the permanent magnet 310 and the outer circle of the motor spindle 100 by supporting the rotor unit 300 through the shaft sleeve 120 with a large diameter, shortens the tension arm of the permanent magnet 310, avoids the resistance to bending moment by increasing the thickness of the main back iron 320, ensures the strength of the rotor unit 300, and avoids the increase of moment of inertia; and the rotational inertia of the motor is reduced through the hollow shaft design, so that the axial flux motor realizes high power. That is, the design of the hollow shaft ensures the strength of the motor main shaft 100 and is beneficial to reducing the moment of inertia and the heat dissipation of the axle center.

In an alternative of this embodiment, the motor spindle 100 may be made of an alloy with good fatigue resistance to make a hollow spindle, and rivet-welding two thin hollow shafts at two ends of the hollow spindle. The hollow shaft is welded by three sections, and the middle section is a large-diameter section. The alloy can be titanium alloy, aluminum alloy and other materials.

Because the permanent magnet 310 is close to the outer circle of the motor main shaft 100, the moment arm is reduced, and the axial flux motor provided by the embodiment does not have the situation that the main back iron 320 bends to cause the permanent magnet 310 to be absorbed with the stator core and be difficult to separate during assembly. Therefore, the air gap can be designed smaller to improve the efficiency of the motor, and the situation that the main back iron 320 bends to cause the stator unit 400 and the rotor unit 300 to be attracted together is avoided, so that the normal operation of the high-power axial flux motor is ensured.

In the present embodiment, the stator unit 400 includes a stator housing 410 and stator windings 420, and a plurality of stator windings 420 are annularly arranged in the stator housing 410 along the circumferential direction of the stator housing 410.

In an alternative of this embodiment, the stator housing 410 includes an upper positioning cover 411, a lower positioning cover 412, an inner ring 413, an outer ring 414 and a lead tube 415, as shown in fig. 13 and 15, the inner ring 413 is inserted into the outer ring 414 and coaxially disposed with the outer ring 414, and the upper positioning cover 411 and the lower positioning cover 412 are respectively connected to two ends of the inner ring 413 and two ends of the outer ring 414, that is, the upper positioning cover 411, the lower positioning cover 412, the inner ring 413 and the outer ring 414 enclose an annular inner cavity. The upper positioning cover plate 411 and the lower positioning cover plate 412 are respectively abutted against two ends of the stator winding 420, and the lead tube 415 is mounted on the upper positioning cover plate 411 and communicated with the annular inner cavity of the stator housing 410, so that the lead wire of the stator winding 420 passes through the lead tube 415 and is led out of the motor housing 200. The stator winding 420 includes a stator core 421 and a coil winding 422 sleeved on the stator core 421.

In this embodiment, the side of the upper positioning cover 411 and the lower positioning cover 412, which are close to each other, are provided with a rib plate 401 and a positioning groove 402, as shown in fig. 16 and 18, and a plurality of rib plates 401 and positioning grooves 402 are annularly and uniformly distributed around the axis of the upper positioning cover 411 and the lower positioning cover 412. Wherein, the rib plate 401 is disposed between two adjacent positioning grooves 402 and extends along the radial direction of the upper positioning cover plate 411 or the lower positioning cover plate 412, so as to improve the strength of the upper positioning cover plate 411 and the lower positioning cover plate 412 and reliably separate the adjacent stator windings 420; the upper and lower ends of the stator winding 420 are respectively clamped in the positioning grooves 402 of the upper positioning cover plate 411 and the lower positioning cover plate 412 to lock the position of the stator winding 420 in the stator housing 410, so that the positioning frame is not required to be used for limiting, the gap between adjacent stator windings 420 is reduced, the full slot rate is improved, meanwhile, the induced current loss and the eddy current loss generated by the metal positioning frame and the blocking of the positioning frame to the cooling liquid are avoided, and the motor efficiency and the cooling effect are improved.

Specifically, the upper and lower ends of the stator core 421 are respectively clamped in the positioning grooves 402 of the upper positioning cover 411 and the lower positioning cover 412; the coil windings 422 are arranged between two adjacent rib plates 401 and are in contact with the rib plates 401, so that limit of the coil windings 422 is achieved, short circuit between the coil windings 422 due to conduction is effectively prevented, winding state of the coil windings 422 is maintained, and looseness caused by factors such as vibration is prevented.

In this embodiment, in order to facilitate the installation of the stator winding 420, the four corners of the positioning groove 402 are provided with circular grooves, and the circular grooves are communicated with the positioning groove 402, as shown in fig. 18, and the four corners of the assembled stator core 421 are clamped into the circular grooves to avoid the increase of repair workload due to the dimension error.

In this embodiment, the outer ring 414, the upper positioning cover 411, the lower positioning cover 412 and the stator winding 420 enclose a first annular flow channel 201; the inner ring 413, the upper positioning cover 411, the lower positioning cover 412 and the stator winding 420 enclose a second annular flow channel 202; the rib plate 401 of the upper positioning cover plate 411, the rib plate 401 of the lower positioning cover plate 412 and the stator winding 420 enclose a radial flow channel 203; the radial flow passage 203 has one end communicating with the first annular flow passage 201 and the other end communicating with the second annular flow passage 202, so that the first annular flow passage 201, the second annular flow passage 202 and the radial flow passage 203 constitute a cooling passage, as shown in fig. 15. The radial flow channels 203 formed between adjacent stator windings 420 avoid the risk of short circuit of the stator windings 420, improve the reliability and safety of the motor, and the rib plates 401 further improve the reliability of the maintaining interval between the stator windings 420.

In this embodiment, the outer ring 414 is provided with cooling ports 204, and two cooling ports 204 are uniformly distributed around the axis of the outer ring 414 and are communicated with the first annular flow channel 201 to serve as an outlet and an inlet of a cooling channel.

In this embodiment, the positioning groove 402 is processed by a numerical control engraving and milling machine to improve the precision and flatness thereof, thereby ensuring accurate positioning and reliable limiting of the stator winding 420, ensuring smoothness of the radial flow channel 203 and improving the reliability and structural strength of the motor.

In an alternative of this embodiment, the upper positioning cover 411 and the lower positioning cover 412 may be manufactured by integral injection molding, and the positioning groove 402 may be obtained directly by injection molding, without machining.

In an alternative of this embodiment, the upper positioning cover 411, the lower positioning cover 412, the inner ring 413, the outer ring 414, and the lead tube 415 are made of non-metallic materials to further reduce eddy current loss and induced current loss, such as glass fiber reinforced PEEK composite, carbon fiber reinforced plastic, glass fiber reinforced plastic, and the like, to which glass fibers are added. Preferably, a glass fiber reinforced PEEK composite material is selected, wherein the content of glass fibers is 15% -40%, and the glass fiber reinforced PEEK composite material is used for guaranteeing the stator housing 410 to have enough strength, toughness and high temperature resistance. Specifically, the material can resist the high temperature of 300 ℃, thereby ensuring the normal operation of the motor.

In this embodiment, the upper positioning cover plate 411 and the lower positioning cover plate 412 are connected with the inner ring 413 and the outer ring 414 by screws, and the joint is sealed by sealant to ensure tightness, so as to avoid liquid leakage. In addition, the lower positioning cover plate 412, the inner ring 413 and the outer ring 414 can be integrally injection molded to further improve the sealing performance, the upper positioning cover plate 411, the inner ring 413 and the outer ring 414 are connected by screws, and the joint is sealed by sealant to ensure the sealing performance.

Specifically, as shown in fig. 19, cylindrical bosses 403 are uniformly distributed on the outer wall of the inner ring 413, first threaded holes 404 coaxial with the cylindrical bosses 403 are provided on the end surface for screw connection with the upper positioning cover 411, and correspondingly, through holes corresponding to the first threaded holes 404 are provided on the upper positioning cover 411. The outer wall of outer ring 414 is provided with spacing draw-in groove 405 that annular was arranged, and the inner wall annular of outer ring 414 is arranged with the rectangle boss 406 that corresponds with spacing draw-in groove 405, is provided with second screw hole 407 and is located the third screw hole 408 on the rectangle boss 406 on the terminal surface of outer ring 414 for with last locating cover 411 screw connection, as shown in fig. 20, correspondingly, last locating cover 411 is last to have seted up the through-hole that corresponds with second screw hole 407 and third screw hole 408. In this embodiment, the cylindrical boss 403 and the rectangular boss 406 are used to improve strength and rigidity; the limiting clamping groove 405 is used for being clamped with a protrusion on the motor housing 200, so that the stator housing 410 and the motor housing 200 are prevented from rotating relatively, and the stator housing 410 is prevented from rotating when the rotor unit 300 rotates, and normal operation of the motor is ensured. Specifically, the retaining groove 405 extends in the axial direction of the outer ring 414.

When the lower positioning cover plate 412 is connected with the inner circular ring 413 and the outer circular ring 414 by bolts, through holes which are the same as the upper positioning cover plate 411 are formed in the lower positioning cover plate, and corresponding first threaded holes 404, second threaded holes 407 and third threaded holes 408 are formed in one ends of the inner circular ring 413 and the outer circular ring 414 connected with the lower positioning cover plate 412.

In addition, a through hole for installing the lead tube 415 is formed in the upper positioning cover 411. During assembly, a sealing ring is arranged in the inner hole of the lead tube 415 to ensure the tightness of the penetration of the lead, thereby ensuring the tightness of the annular inner cavity of the stator housing 410. In addition, the oil-resistant rubber tube can be sleeved outside the lead tube 415 and the lead, the end part of the oil-resistant rubber tube sleeved on the lead tube 415 is tightly sealed, the outer joint of the lead is tightly pressed by a copper tube with a plug in the middle and then penetrates into the oil-resistant rubber tube to be tightly sealed, the other end of the copper tube is directly connected with the lead of the driving system in a crimping way, and the tightness of the annular inner cavity of the stator shell 410 is ensured. In short, the copper pipe with the middle seal is used as the adapter, one end is inserted with the lead wire, the other end is inserted with the lead wire of the driving system, the lead wire of the stator winding 420 is connected with the lead wire of the driving system in a crimping way, and at the moment, the liquid in the stator shell 410 cannot flow out along the lead wire; meanwhile, the copper pipe is inserted into the lead pipe 415, and an oil-resistant rubber pipe is sleeved outside the lead pipe 415 and tightly hooped to seal the gap between the lead pipe 415 and the copper pipe, so that a seal is formed.

In this embodiment, the stator unit 400 is provided with the rib plate 401 on one side of the upper positioning cover plate 411 and the lower positioning cover plate 412, which are close to each other, so as to improve the strength of the upper positioning cover plate 411, the lower positioning cover plate 412 and the stator housing 410, thereby preventing the stator housing 410 from being deformed, ensuring the strength of the non-metal housing without internal glue injection, and avoiding the leakage of the cooling liquid caused by the heated deformation of the glue injection layer, and further ensuring the protection performance and the safety of the motor. In addition, the maintainability of the stator unit 400 is improved without glue injection, when part of the stator windings 420 are damaged, only the stator housing 410 is required to be opened and the damaged stator windings 420 are replaced, and the glue injection mode is that glue injection layers are inserted into two ends of the stator windings 420, once the stator windings 420 are damaged, the stator windings 420 are difficult to repair and replace, the adhered glue is difficult to take out, the adhered glue is difficult to clean and cannot be reassembled, if the glue injection layers are required to be completely removed and the glue injection is required to be re-performed during the reassembling, and the cost is extremely high.

In this embodiment, taking the height of the stator winding 420 as an example of 100mm, the height of the rib 401 is set to 20mm, and the height of the radial flow channel 203 is set to 60mm. This height ensures both the strength of the stator housing 410 and the adequate contact of the coolant with the stator windings 420, thereby ensuring cooling and insulation.

In operation, the two cooling ports 204 serve as an oil inlet and an oil outlet for cooling medium to enter and exit, respectively, and cooling medium enters from the oil inlet and flows through the first annular runner 201, the second annular runner 202 and the radial runner 203 to achieve sufficient cooling of the stator winding 420 and flows out from the oil outlet. The radial flow channel 203 is arranged to fully cool the stator winding 420, so that the situation that the temperature of the side surface of the stator winding 420 is too high and the temperature of the two ends of the stator winding, which are close to the inner ring 413 and the outer ring 414, is lower is avoided, the cooling effect is remarkably improved, and the overload capacity of the motor is further improved. The cooling medium may be selected from a cooling liquid or a gas. Meanwhile, as the rotor unit 300 rotates, the air circulation path inside the motor housing 200 circulates to uniformly distribute heat, and when gas flows through the air gap between the rotor unit 300 and the stator unit 400, the gas and the stator housing 410 may exchange heat to balance the heat. When the temperature of the gas is high, the gas can be cooled by the cooling capacity of the cooling channel, so that the temperature inside the motor shell 200 is controlled, and the phenomenon that the temperature cannot be timely dissipated is prevented; when the temperature of the stator unit 400 is high, the gas may assist in heat dissipation of the stator housing 410. Namely, the circulating air passage and the cooling passage are matched with each other, so that the heat in the motor is balanced, the heat dissipation capacity is improved, and the stable operation of the motor is ensured.

Based on the integrated cooling system provided by the embodiment, an axial flux motor is provided, which comprises the integrated cooling system. The axial flux motor provided by the embodiment can have excellent overload capacity due to the cooling capacity and the efficiency of the integrated cooling system, and ensures the safe and stable operation of the motor. The air gap formed by the stator unit 400 and the rotor unit 300 ensures that negative pressure generated by the radial air channel 101 can effectively drive air in the main shaft cavity 105 to flow out, so that air circulates smoothly and fully flows through each part, the speed of air circulation is ensured, thereby realizing effective heat dispersion, avoiding that heat of the motor main shaft 100 cannot be taken away in time, preventing the motor main shaft 100 from overheat and expanding, affecting the cooperation between parts, and causing abnormal sound, friction increase and other conditions during motor operation. Meanwhile, based on the improvement of the cooling capacity and the cooling efficiency, the motor can have 150% of overload capacity and 98% of higher energy efficiency, and extremely high energy saving and consumption reduction are realized.

Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present invention, and not for limiting the same; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some or all of the technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit of the invention.

Claims

1. An integrated heat dissipation system, characterized by comprising a motor main shaft (100), a motor housing (200), a rotor unit (300) and a stator unit (400);

The motor main shaft (100) is rotatably arranged in the motor shell (200), and the rotor unit (300) and the stator unit (400) are sleeved on the motor main shaft (100) and are arranged in the motor shell (200);

One side of the rotor unit (300) is provided with a radial air passage (101), the other side of the rotor unit and the motor shell (200) enclose a backflow air passage (103), and the outer circle of the rotor unit (300) and the motor shell (200) enclose a communication air passage (102); the motor spindle (100) is provided with a spindle inner cavity (105), and an air return hole (104) and an air outlet hole (106) which are communicated with the spindle inner cavity (105);

the radial air passage (101), the communicating air passage (102), the backflow air passage (103), the return air hole (104), the main shaft inner cavity (105) and the air outlet hole (106) are sequentially communicated to form a circulating air passage;

A first annular flow passage (201), a second annular flow passage (202) and a radial flow passage (203) are arranged in the stator unit (400); one end of the radial flow channel (203) is communicated with the first annular flow channel (201), and the other end of the radial flow channel is communicated with the second annular flow channel (202); the first annular flow passage (201), the second annular flow passage (202) and the radial flow passage (203) form a cooling passage;

the rotor unit (300) comprises a plurality of permanent magnets (310) which are uniformly distributed around the axis of the rotor unit, and gaps between the adjacent permanent magnets (310) form the radial air passage (101);

The motor spindle (100) comprises an output shaft (110) and a shaft sleeve (120), wherein the shaft sleeve (120) is sleeved on the output shaft (110) and forms an annular spindle inner cavity (105) with the output shaft (110);

The shaft sleeve (120) is provided with the air outlet hole (106);

the motor main shaft (100) further comprises shaft covers (130), and the two shaft covers (130) are sleeved on the output shaft (110) and connected with the output shaft (110);

the two shaft end covers (130) are inserted into the shaft sleeve (120) and enclose the main shaft inner cavity (105) together with the shaft sleeve (120) and the output shaft (110);

The shaft end cover (130) is provided with the return air hole (104);

The stator unit (400) comprises a stator housing (410) and stator windings (420), a plurality of the stator windings (420) being annularly arranged within the stator housing (410);

the stator housing (410) comprises an upper positioning cover plate (411), a lower positioning cover plate (412), an inner circular ring (413) and an outer circular ring (414);

The inner ring (413) is inserted into the outer ring (414) and is coaxially arranged with the outer ring (414); the upper positioning cover plate (411) and the lower positioning cover plate (412) are respectively connected to two ends of the inner circular ring (413) and two ends of the outer circular ring (414);

The upper positioning cover plate (411) and the lower positioning cover plate (412) are respectively abutted to two ends of the stator winding (420);

the outer ring (414), the upper positioning cover plate (411), the lower positioning cover plate (412) and the stator winding (420) enclose a first annular flow channel (201);

the inner ring (413), the upper positioning cover plate (411), the lower positioning cover plate (412) and the stator winding (420) enclose a second annular flow channel (202);

The upper positioning cover plate (411), the lower positioning cover plate (412) and the stator winding (420) enclose a radial flow channel (203).

2. The integrated heat dissipation system of claim 1, wherein the rotor unit (300) further comprises a main back iron (320) and a limiting cover plate (330);

The permanent magnet (310) is arranged on the main back iron (320), and a limiting hole is formed in the limiting cover plate (330);

The permanent magnet (310) is inserted into the limiting hole, and one end of the permanent magnet (310) protruding out of the limiting cover plate (330) and the limiting cover plate (330) enclose the radial air passage (101).

3. The integrated heat dissipation system according to claim 1, wherein the outer ring (414) is provided with cooling ports (204), and two cooling ports (204) are uniformly distributed around the axis of the outer ring (414) and are communicated with the first annular flow channel (201).

4. A comprehensive heat dissipation system according to claim 3, wherein the side of the upper positioning cover plate (411) and the side of the lower positioning cover plate (412) close to each other are provided with rib plates (401), and the rib plates (401) of the upper positioning cover plate (411) extend along the radial direction of the upper positioning cover plate (411); the rib plate (401) of the lower positioning cover plate (412) extends along the radial direction of the lower positioning cover plate (412);

Positioning grooves (402) are formed in the upper positioning cover plate (411) and the lower positioning cover plate (412), and the rib plates (401) are arranged between two adjacent positioning grooves (402);

the stator winding (420) comprises a stator core (421) and a coil winding (422) sleeved on the stator core (421);

Two ends of the stator core (421) are respectively abutted against the positioning grooves (402) of the upper positioning cover plate (411) and the lower positioning cover plate (412);

The coil windings (422) are arranged between two adjacent rib plates (401) and are in contact with the rib plates (401).

5. The integrated heat dissipation system as recited in claim 1, wherein the upper positioning cover plate (411) is connected with the inner ring (413) and the outer ring (414) by screws, and joints are sealed by sealant;

The lower positioning cover plate (412) is integrally injection molded with the inner ring (413) and the outer ring (414) or connected by screws, and the joint is sealed by using sealant.

6. An axial flux electric machine comprising an integrated heat dissipation system as defined in any one of claims 1-5.