CN108270301B - Stator structure with winding end cooling structure and motor thereof - Google Patents
Stator structure with winding end cooling structure and motor thereof Download PDFInfo
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- CN108270301B CN108270301B CN201810074462.6A CN201810074462A CN108270301B CN 108270301 B CN108270301 B CN 108270301B CN 201810074462 A CN201810074462 A CN 201810074462A CN 108270301 B CN108270301 B CN 108270301B
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/12—Stationary parts of the magnetic circuit
- H02K1/20—Stationary parts of the magnetic circuit with channels or ducts for flow of cooling medium
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Abstract
The invention discloses a stator structure with a winding end cooling structure and a motor thereof, wherein the stator structure comprises: the stator core, the winding and the stator encapsulation structure are fixed on the stator core, the stator encapsulation structure is formed by encapsulating and fixing an in-groove gap of the stator core and the end part of the winding by adopting a non-magnetic material, an annular cavity, a cooling liquid inlet and a cooling liquid outlet are formed in the stator encapsulation structure, and the annular cavity is close to the end part of the winding; and circulating cooling liquid is introduced into the annular cavity through the cooling inlet and the cooling liquid outlet to realize the cooling of the end part of the winding. The end part cooling structure provided by the invention has the functions of winding fixing and insulation, the circularly flowing cooling liquid is directly contacted with the winding in the annular cavity of the end part, the heat dissipation effect can be obviously improved, the cooling structure can be prepared by the existing encapsulation process, the structure is simple, the manufacturing is convenient, and the influence on the performance of the motor is small.
Description
Technical Field
The invention belongs to the technical field of motors, and particularly relates to a stator structure with a winding end cooling structure and a motor thereof.
Background
In recent years, due to the non-renewable nature of fossil energy and the increasing environmental problems, the research and development of electric vehicles have been paid attention from various researchers and automobile manufacturers, and the related technologies have been advanced. The existing electric automobile mainly adopts a centralized driving system, namely a driving motor is positioned in the automobile and outputs power to wheels through a transmission system; in contrast, an electric wheel drive system is known, i.e. the electric motor is mounted directly in the wheel.
Compared with the traditional driving mode, the electric wheel driving system has the advantages in multiple aspects: (1) the structure is simple, a complex mechanical transmission system is omitted, the structure of the chassis is simplified, the space in the vehicle is greatly increased, and the riding comfort is improved; (2) the electric braking of the vehicle can be realized, and the energy utilization rate is improved; (3) each hub motor is independently controllable, the turning flexibility of the vehicle can be improved, and a differential device is omitted.
Although in-wheel motor drive systems have many advantages, there are still some problems restricting their development and widespread use: (1) the hub motor needs to be arranged in an in-wheel space, the structural size of the hub limits the outer diameter of the motor, and the axial length of a suspension device of an automobile limits the axial length of the suspension device, so that the hub motor has the requirement of small size; (2) the hub motor is positioned in the wheel, so that unsprung mass of the automobile can be increased, riding comfort, driving smoothness and control stability of the automobile are influenced, and the hub motor is very sensitive to the mass of the motor; (3) the direct-driven hub motor does not have a speed reduction device, large torque needs to be output, and the motor is located in the hub, so that the heat dissipation condition is severe.
Because the wheel hub motor usually adopts the outer rotor structure, the common problem that the immersion type oil cooling in the new energy automobile faces the difficulty of dynamic sealing, so the application in the wheel hub motor is less. Most existing in-wheel motor cooling systems are provided with a circulating water channel in a shell of the motor or a water cooling plate structure is added at the end part of the motor while the circulating water channel is arranged. The direct-drive hub motor belongs to a low-speed large-torque application occasion, the copper consumption of the motor is obviously improved due to a large torque requirement, and a winding becomes a main heat source of the motor. When only the circulating water path is used, the winding, particularly the end part of the winding, is not directly contacted with the cooling plate and needs to be conducted through the iron core, so that the heat dissipation efficiency is low, the problem of local overheating exists, and the operation safety and the service life of the motor can be directly influenced; the end part water cooling plate structure can solve the problem of end part heat dissipation, but can cause larger eddy current loss, and can increase the weight of the motor. How to effectively radiate heat without increasing the complexity and weight of the system is a major technical difficulty of the hub motor.
In sum, the hub motor has the characteristics of high torque density and high power density, and has high requirements on a heat dissipation system.
Fig. 1 is a schematic structural diagram of a novel cooling type in-wheel motor, in which a front end cover 1 is connected with a housing 2. The rotor 3 is installed at the inner circumference of the housing 2. The bracket 5 is located at the inner circle of the stator 4, and supports and fixes the stator 4. The bracket 5 is connected with the rotating shaft 7 through a bearing 8. The rotating shaft 7 is connected with a rear end cover 6 positioned on the right side of the motor through a bolt. A cooling flow passage is arranged in the bracket 5 with the end plate cylindrical shape at one end, and a cooling medium is filled in the cooling flow passage. The inner wall of the stator core is contacted with the outer wall of the cylinder section of the bracket 5, and the end part of the stator winding is contacted with the inner vertical surface of the end plate of the bracket 5. The cooling flow channels are positioned on the wall surface of the cylinder section of the support and in the end plate of the support, and the two parts of the cooling flow channels are communicated through the communication holes. The hub motor is suitable for new energy automobile motors and outer rotor motors. However, the hub motor has the following disadvantages:
(1) although the hub motor can achieve a good cooling effect on the stator core and the winding end part, the cooling device greatly increases the complexity of the system and improves the processing and assembling difficulty;
(2) the technical background shows that the performance of the electric wheel is very sensitive to the weight of the system, and the cooling device of the hub motor obviously increases the overall weight of the system and possibly reduces the comfort, braking and steering performance of a vehicle;
(3) the direct contact of the end plates of the support with the end portions of the windings may cause large eddy current losses, which reduces the efficiency of the machine and the end portions may only directly cool the end portions on one side thereof, while the end portions on the other side may still be overheated.
Fig. 2 is a schematic structural diagram of a motor winding end cooling structure, which adopts an isolation sleeve 4 to form a sealed cavity with a casing 1 and an end cover 5, a sealed space at the end is filled with cooling oil, the end cover is provided with an oil inlet and an oil outlet, and the end cover is connected with an external pump 7 and a radiator 8 to form a circulating oil cooling loop, so that heat is effectively dissipated. However, the motor winding end cooling structure has the following disadvantages:
(1) although the cooling structure of the end part of the motor winding obtains better cooling effect by using a direct oil cooling mode, the cooling structure has high requirements on the matching and sealing of the isolation sleeve and each component of the shell, and the problem of leakage of cooling liquid is easy to occur;
(2) the isolation sleeve structure is positioned between the stator and the rotor of the motor, so that the air gap length of the motor is greatly increased, the performance of the motor is reduced, and high requirements on processing precision are provided;
(3) the large cooling cavity is filled with a large amount of cooling liquid, so that the overall weight of the electric wheel is increased, a large-capacity pump and a large-capacity radiator are required to be arranged, and the cost of a cooling system is greatly increased.
Disclosure of Invention
In view of the above defects or improvement requirements of the prior art, the present invention provides a stator structure with a winding end cooling structure, and aims to solve the technical problem that the cooling structure in the existing motor cannot give consideration to both simple structure and good cooling performance.
To achieve the above object, the present invention provides a stator structure having a winding end portion cooling structure, comprising:
the stator core, the winding and the stator encapsulation structure are fixed on the stator core, the stator encapsulation structure is formed by encapsulating and fixing an in-groove gap of the stator core and the end part of the winding by adopting a non-magnetic material, an annular cavity, a cooling liquid inlet and a cooling liquid outlet are formed in the stator encapsulation structure, and the annular cavity is close to the end part of the winding; and circulating cooling liquid is introduced into the annular cavity through the cooling inlet and the cooling liquid outlet to realize the cooling of the end part of the winding.
Preferably, part of the cavity wall of the annular cavity is formed by the winding heads.
Preferably, the annular cavity is located in the annular space in which the winding overhang is shaped, or on the winding overhang side, or surrounds the entire winding overhang.
As another aspect of the present invention, the present invention provides an electric machine based on the above stator having a winding end portion cooling structure, including: a stator and a rotor having a winding end portion cooling structure.
The invention provides a slotless hub motor, which aims to meet the requirements of miniaturization and light weight of a hub motor and solve the problems of multiple times of winding heat transfer, difficulty in heat dissipation, complex heat dissipation system and large self weight in the existing hub motor heat dissipation technology.
In order to achieve the above object, the present invention provides an in-wheel motor based on the above stator, including: the stator is provided with a winding end cooling structure, and comprises a stator bracket, a rotor bracket and magnetic steel; the stator with the winding end cooling structure is positioned on a stator support, the magnetic steel is positioned on a rotor support, the stator support is used for being connected with a suspension frame bridge, and the rotor support is connected with a rotating shaft.
Preferably, the stator core is a slotless core.
Preferably, an insulating framework is nested on the stator core, a groove is formed in the framework, and the framework is used for fixing a winding and insulating.
Preferably, the magnetic steel is magnetized by a Halbach array.
In general, compared with the prior art, the above technical solution contemplated by the present invention can achieve the following beneficial effects:
1. the stator structure provided by the invention is characterized in that on the basis of the existing winding encapsulation construction, the winding encapsulation construction close to the end part of the winding is provided with the annular cavity, the cooling liquid inlet and the cooling liquid outlet, the cooling liquid is injected into the annular cavity through the cooling liquid inlet and the cooling liquid outlet, the winding is directly cooled, the cooling effect is good, the cooling structure is manufactured by using the existing encapsulation technology, the preparation steps are simple, the annular cavity for cooling is arranged in the encapsulation part, the influence on the structure of the motor is small, and the cooling effect of the end part of the winding can be improved under the condition of ensuring that the performance of the motor is not changed.
2. The stator structure provided by the invention can be suitable for stators with different structures and is wide in application.
3. The hub motor provided by the invention adopts the stator with the winding end part cooling structure, the cooling liquid is directly contacted with the winding end part and circularly flows in the end part cavity, the heat generated by the winding can be quickly and effectively taken away, the heat dissipation capability of the motor is obviously improved, the temperature rise is reduced, the long-term safe operation of the motor is ensured, the structure is simple, and the additional cooling structure and the weight cannot be increased.
Drawings
FIG. 1 is a schematic structural diagram of a wheel hub motor with a novel cooling method in the background art;
FIG. 2 is a schematic structural diagram of a cooling structure for a winding head of a motor in the prior art;
FIG. 3 is a schematic view of a winding head cooling structure provided by the present invention;
FIG. 4(a) is a schematic diagram of a stator structure having a distributed winding overhang cooling configuration provided by the present invention; fig. 4(b) is a schematic view of a stator structure having a concentrated winding end cooling structure provided by the present invention;
FIG. 5 is a cross-sectional view of the in-wheel motor provided by the present invention;
FIG. 6 is a partial enlarged view of a stator structure of the in-wheel motor according to the present invention;
FIG. 7 is a schematic view of the rotor magnetization of the in-wheel motor provided by the present invention;
fig. 8 is an exploded view of a stator structure of the in-wheel motor provided by the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
Fig. 3 is a schematic view of a winding end cooling structure provided by the present invention, after the winding is taken off line, the winding is usually encapsulated with a non-magnetic material, such as epoxy resin, to perform the functions of winding fixation and insulation, unlike the encapsulation of a conventional motor, the winding encapsulation of the motor of the present invention is not a solid structure, during encapsulation, an annular cavity 103 is formed at each of two side ends of the winding, a part of the cavity wall of the annular cavity is composed of the winding end, the annular cavity is filled with a heat-conducting and insulating cooling liquid, such as transformer oil, a pair of cooling liquid inlet 101 and cooling liquid outlet 102 is formed at each of two sides of the encapsulation piece, and both the cooling liquid inlet 101 and the cooling liquid outlet are connected with the annular cavity and are connected to an external radiator and an external oil pump through pipes. The cooling liquid directly contacts with the winding, the cooling effect is good, and the preparation method of the potting piece is simple.
The winding end cooling structure provided by the invention is also applicable to various slotted motors, and fig. 4(a) is a schematic diagram of a stator structure with a distributed winding end cooling structure provided by the invention, the end of the distributed winding is a spatial arc line in the circumferential direction, an annular cavity is formed at the end of the winding, and the annular cavity can be formed by directly utilizing the end gap during encapsulation. Fig. 4(b) is a schematic diagram of a stator structure with a concentrated winding end cooling structure provided by the present invention, a radial section of the concentrated winding end is a solid structure, and a gap may be reserved on one side of the winding during potting or a C-shaped cavity may be directly potted to wrap the end therein. Through being full of the circulating coolant liquid in the cavity, the tip embedment structure has not only played original fixed, insulating effect, can also carry out direct infiltration formula oil to the winding and cool, has improved motor heat-sinking capability greatly, reaches the effect that promotes torque output ability.
The invention provides an in-wheel motor. Fig. 5 is a sectional view showing the overall structure of the motor. The hub motor comprises a rotor bracket 6, a stator bracket 4, magnetic steel 5, a stator yoke 3 and a winding 2 with a potting part 1. The rotor bracket 6 and the stator bracket 4 are both made of light metal alloy materials; the motor has a shell-less structure, a rotor bracket 6 is provided with a bearing 7, the rotor bracket 6 is connected with a rotating shaft 8 through a bolt, and the outer side of the rotor bracket is directly fixed with an automobile hub and a tire structure; the stator support 4 is fixed on the suspension bridge through bolts.
Fig. 6 is a partial enlarged view of the stator structure in the hub motor, the winding 2 is wound on the stator core 1, an annular cavity is formed in the end portion of the winding 2, and the cavity on the potting piece 3 is arranged in the annular cavity of the end portion of the winding, so that the internal space of the winding is fully utilized, the performance of the motor is guaranteed, and the cooling efficiency of the end portion of the winding is improved.
The magnetic steel 5 of the hub motor is fixed on the inner side of the rotor bracket 6 and is magnetized by adopting a Halbach array, and the magnetizing direction of the Halbach array is shown in figure 7. The conventional permanent magnet motor adopts single radial magnetization or tangential magnetization, so that the air gap flux density waveform is close to a square wave, and larger harmonic content exists. One magnetic pole of the Halbach array magnetic steel is composed of a plurality of magnetizing units, the magnetizing direction of each unit is different, and the Halbach array can provide a nearly sinusoidal air gap flux density waveform and a larger air gap flux by adjusting the direction and the size of each magnetizing unit, so that the eddy current loss can be effectively reduced, and the torque output is improved. In addition, the Halbach array has a good magnetic shielding effect, the thickness of a rotor yoke can be obviously reduced, and even the rotor yoke is omitted, so that the weight of a rotor is reduced, the effective radius of the magnetic steel is increased at a certain time when the outer diameter of the motor is constant, and the torque can be further improved.
The stator core without the slot of the hub motor is formed by laminating silicon steel sheets and is nested outside the stator support, and fig. 8 shows an explosion view of the stator structure. Unlike the conventional stator, the proposed stator is a slotless structure having only a yoke, and the yoke portion of the multi-pole motor is thin, so that the core weight is significantly reduced. A layer of slotted framework 9 made of insulating materials is fixed outside the slotless iron core in a nested mode, the number of slots of the slotted framework corresponds to the number of tooth slots of a conventional stator, and the slotted framework plays a role in positioning and insulating windings. Because the stator does not have teeth and only comprises a layer of magnetic yoke, and the insulating framework 9 is very light and thin and is similar to the insulating layer of the conventional motor slot in thickness, the space can be more fully utilized, the section proportion of a winding conductor is obviously increased, and the copper consumption of the motor is reduced. In further consideration, the motor is not influenced by the cogging-free saturation of the stator core, so that the torque output capacity and the current linearity of the motor are good, and the overload capacity is strong. In addition, the slotless hub motor has the advantage of small torque ripple because of no cogging.
The direct-drive electric wheel system belongs to the application occasion of low speed and large torque, and the copper consumption of the direct-drive electric wheel system is obviously higher than other loss components. Because the Halbach array magnetic steel is adopted and a stator tooth groove structure is not adopted, the magnetic steel loss and the stator iron loss are further reduced, and the motor winding is a main heat source of the slotless hub motor. In the cooling structure, the cooling liquid is in direct contact with the end part of the winding and circularly flows in the cavity of the end part, so that the heat generated by the winding can be quickly and effectively taken away, the heat dissipation capability of the motor is obviously improved, the temperature rise is reduced, the long-term safe operation of the motor is ensured, the structure is simple, and the additional cooling structure and the weight cannot be increased.
In summary, the slotless hub motor provided by the invention adopts the Halbach array permanent magnet rotor and slotless stator structure, so that the effective weight of the motor is obviously reduced, the torque density and the overload capacity of the motor are improved, the cogging effect is eliminated, the torque stability is improved, and the loss is reduced. The cooling mode of the motor adopts the winding end part to be encapsulated to form an annular cavity, the cavity is filled with insulating cooling liquid to be connected with an external radiator and a pump, circulating oil cooling is realized, the circulating oil cooling is realized while fixation and insulation are realized, the winding serving as a main heat source is effectively cooled, the excellent cooling effect can be achieved, and the motor has the advantages of simple structure, light weight and no need of an additional complex cooling device. In addition, the winding end cooling structure provided by the invention has no influence on an air gap between the stator and the rotor, and the performance of the motor is not reduced while the winding cooling effect is improved.
It will be understood by those skilled in the art that the foregoing is only a preferred embodiment of the present invention, and is not intended to limit the invention, and that any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (6)
1. A stator structure with a winding end cooling structure is characterized by comprising a stator core, a winding and a stator encapsulation structure, wherein the winding is fixed on the stator core, the stator encapsulation structure is formed by encapsulating and fixing an in-groove gap of the stator core and the winding end by adopting a non-magnetic material, an annular cavity, a cooling liquid inlet and a cooling liquid outlet are formed in the stator encapsulation structure, and the annular cavity is close to the winding end; circulating cooling liquid is introduced into the annular cavity through a cooling inlet and a cooling liquid outlet to cool the end part of the winding, wherein the cooling liquid is transformer oil; part of the cavity wall surface of the annular cavity is formed by winding end parts; the annular cavity is located in the annular space of the shaped winding head, or on the winding head side, or surrounds the entire winding head.
2. An electric machine based on the stator structure of claim 1, characterized by comprising: a stator and a rotor having a winding end portion cooling structure.
3. An in-wheel motor based on the stator structure of claim 2, comprising: the stator is provided with a winding end cooling structure, and comprises a stator bracket, a rotor bracket and magnetic steel; the stator with the winding end cooling structure is positioned on a stator support, the magnetic steel is positioned on a rotor support, the stator support is used for being connected with a suspension frame bridge, and the rotor support is connected with a rotating shaft.
4. The in-wheel motor of claim 3, wherein the stator core is a slotless core.
5. The in-wheel motor according to claim 4, wherein an insulating framework is nested on the stator core, slots are formed in the framework, and the framework is used for fixing windings and insulating.
6. An in-wheel motor according to any one of claims 3 to 5, characterized in that the magnetic steel is magnetized by a Halbach array.
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| Application Number | Priority Date | Filing Date | Title |
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| CN201810074462.6A CN108270301B (en) | 2018-01-25 | 2018-01-25 | Stator structure with winding end cooling structure and motor thereof |
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| CN201810074462.6A CN108270301B (en) | 2018-01-25 | 2018-01-25 | Stator structure with winding end cooling structure and motor thereof |
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| CN108270301A CN108270301A (en) | 2018-07-10 |
| CN108270301B true CN108270301B (en) | 2020-06-26 |
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Families Citing this family (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108768009A (en) * | 2018-07-27 | 2018-11-06 | 深圳市泉胜新技术开发有限公司 | A kind of automobile primary drives the stator core fixed structure of motor |
| CN109525056A (en) * | 2019-01-14 | 2019-03-26 | 苏州阿福机器人有限公司 | A kind of oil-cooled motor |
| CN110011456A (en) * | 2019-05-12 | 2019-07-12 | 苏州新智机电工业有限公司 | A kind of assembled piece type stator winding end wiring construction |
| CN111049326A (en) * | 2020-01-21 | 2020-04-21 | 浙江绿源电动车有限公司 | Hub motor with built-in charging system |
| CN113675966B (en) * | 2021-09-14 | 2023-11-24 | 无锡星驱科技有限公司 | Stator assembly, motor and motor cooling system |
| CN113872367A (en) * | 2021-09-22 | 2021-12-31 | 东风电驱动系统有限公司 | In-wheel motor |
| CN114157097B (en) * | 2021-11-18 | 2023-09-26 | 东南大学 | Stator structure of magnetic suspension magnetic flux switching motor |
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| CN202309459U (en) * | 2011-10-27 | 2012-07-04 | 北京万源工业有限公司 | Permanent magnet direct-driven type synchronous wind-driven generator with outer rotor |
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| CN206775255U (en) * | 2017-01-26 | 2017-12-19 | 上海蔚来汽车有限公司 | Stator module, Stator and electrical machine |
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| CN202309459U (en) * | 2011-10-27 | 2012-07-04 | 北京万源工业有限公司 | Permanent magnet direct-driven type synchronous wind-driven generator with outer rotor |
| CN105576863A (en) * | 2015-12-29 | 2016-05-11 | 哈尔滨理工大学 | Direct-cooling direct-drive type motor with copper tube structured stator |
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