WO2023108918A1 - 定子组件、轮毂电机及电动车 - Google Patents

定子组件、轮毂电机及电动车 Download PDF

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Publication number
WO2023108918A1
WO2023108918A1 PCT/CN2022/079099 CN2022079099W WO2023108918A1 WO 2023108918 A1 WO2023108918 A1 WO 2023108918A1 CN 2022079099 W CN2022079099 W CN 2022079099W WO 2023108918 A1 WO2023108918 A1 WO 2023108918A1
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WO
WIPO (PCT)
Prior art keywords
stator
hall plate
hall
bracket
stator assembly
Prior art date
Application number
PCT/CN2022/079099
Other languages
English (en)
French (fr)
Inventor
左亚军
刘俊峰
Original Assignee
威灵（芜湖）电机制造有限公司
广东威灵电机制造有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from CN202123196345.3U external-priority patent/CN216625395U/zh
Priority claimed from CN202111546612.7A external-priority patent/CN114243958A/zh
Application filed by 威灵（芜湖）电机制造有限公司, 广东威灵电机制造有限公司 filed Critical 威灵（芜湖）电机制造有限公司
Publication of WO2023108918A1 publication Critical patent/WO2023108918A1/zh

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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
    • H02K1/14—Stator cores with salient poles
    • 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
    • H02K1/18—Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/64—Electric machine technologies in electromobility

Definitions

  • the present disclosure relates to the technical field of motors, in particular to a stator assembly, a hub motor and an electric vehicle.
  • the Hall sensor in the hub motor, and the Hall sensor is usually installed in the stator core. It is necessary to open a sensor installation slot in the stator core, and fix the Hall sensor by cold pressing or gluing process. In the mounting slot, the Hall sensor senses the magnetic field of the permanent magnet of the rotor assembly in the radial direction.
  • the sensor installation groove affects the performance of the motor to a certain extent, and the installation process of the Hall sensor is complicated and needs to be improved.
  • the present disclosure aims to solve at least one of the technical problems existing in the prior art. For this reason, the present disclosure proposes a stator assembly, the installation process of the Hall sensor is simple, and the reliability of the Hall sensor is effectively improved.
  • the present disclosure also proposes an in-wheel motor having the above-mentioned stator assembly.
  • the present disclosure also proposes an electric vehicle having the above in-wheel motor.
  • the stator assembly includes a stator core, a stator bracket, a support bracket and a Hall plate, the stator core has a closed yoke, and the outer periphery of the yoke is provided with a plurality of teeth part, the teeth are connected with windings, the stator bracket is fixedly connected to the stator core, the stator bracket is located inside the yoke, the support bracket is connected to the stator bracket, the support The bracket is provided with at least one Hall plate mounting frame, the Hall plate is connected to the Hall plate mounting frame, the Hall plate is connected with at least one Hall sensor, along the radial direction of the stator core, The Hall sensor is located outside the winding.
  • the stator assembly has at least the following beneficial effects: the stator bracket of the stator assembly is connected with a supporting bracket, the supporting bracket is installed with a Hall plate through a Hall plate mounting bracket, and the Hall sensor is connected to the Hall plate.
  • the Hall sensor is located on the outside of the winding, corresponding to the permanent magnet of the rotor assembly, which can sense the magnetic field at the axial end of the rotor permanent magnet; the stator assembly uses a Hall plate to install the Hall sensor, eliminating the need for A sensor installation slot is opened in the middle to prevent the electromagnetic performance of the stator assembly from being affected, which is conducive to improving the performance of the hub motor.
  • the support bracket is provided with a plurality of the Hall plate mounting brackets, and the plurality of Hall plate mounting brackets are distributed at intervals along the circumference of the support bracket.
  • the support bracket is provided with three Hall plate mounting frames, and the Hall plate is arc-shaped and connects the three Hall plate mounting frames.
  • the Hall plate installation frame is provided with a first connecting piece, and the Hall plate is provided with a mounting hole matching the first connecting piece.
  • the first connecting piece includes a plurality of uprights, the plurality of uprights are distributed in the circumferential direction, the ends of the uprights are provided with stoppers, and the stoppers abut against the Hall plate.
  • the Hall plate mounting frame is provided with a rib, and the rib plate and the first connecting member are arranged on two opposite surfaces of the Hall plate mounting frame, so The ribs are connected to the supporting brackets.
  • the support bracket is provided with a plurality of second connectors, the plurality of second connectors are distributed along the circumference of the support bracket, and the second connectors Attach the stator bracket.
  • the supporting bracket is provided with a plurality of cross-slot connection lines, and the cross-slot connection lines are electrically connected to the windings.
  • the in-wheel motor according to the embodiment of the second aspect of the present disclosure includes the stator assembly of the embodiment of the first aspect.
  • the hub motor includes a central shaft, the stator assembly is fixedly connected to the central shaft, and a rotor assembly is supported on the central shaft through a bearing, and the rotor assembly has a permanent magnet along the In the radial direction of the central axis, the Hall sensor corresponds to the position of the permanent magnet.
  • the distance between the Hall sensor and the permanent magnet is L, which satisfies 1mm ⁇ L ⁇ 4mm.
  • the electric vehicle according to the embodiment of the third aspect of the present disclosure includes the in-wheel motor of the embodiment of the second aspect.
  • FIG. 1 is a cross-sectional view of an in-wheel motor according to a second aspect of the present disclosure
  • Fig. 2 is a first structural schematic diagram of a stator assembly according to an embodiment of the first aspect of the present disclosure
  • Fig. 3 is a second structural schematic diagram of the stator assembly of the embodiment of the first aspect of the present disclosure
  • Fig. 4 is a first structural schematic diagram of a support bracket and a Hall plate in an embodiment of the first aspect of the present disclosure
  • Fig. 5 is a second structural schematic diagram of the support bracket and the Hall plate in the embodiment of the first aspect of the present disclosure
  • Fig. 6 is a schematic structural diagram of a support bracket in an embodiment of the first aspect of the present disclosure
  • Fig. 7 is a structural schematic diagram 1 of removing the cross-trough connecting line of the support bracket in the embodiment of the first aspect of the present disclosure
  • Fig. 8 is a structural schematic diagram 2 of removing the cross-trough connecting line of the support bracket in the embodiment of the first aspect of the present disclosure
  • Fig. 9 is an enlarged view of place A in Fig. 7;
  • Fig. 10 is a structural schematic diagram 1 of the rotor assembly in the embodiment of the second aspect of the present disclosure.
  • Fig. 11 is a second structural schematic diagram of the rotor assembly in the embodiment of the second aspect of the present disclosure.
  • Fig. 12 is an exploded schematic view of the rotor assembly in the embodiment of the second aspect of the present disclosure.
  • Housing assembly 200 grease sealing cavity 201, main housing 210, second retaining ring 211, auxiliary housing 220, rim 230;
  • Stator assembly 300 Winding 310, stator core 320, tooth portion 321, yoke portion 322, stator bracket 330, bushing 331 support bracket 340, Hall plate mounting frame 341, rib plate 3411, first connecting piece 342, column 3421, a stopper 3422, a second connecting piece 343, a cross-slot connection line 344, a Hall plate 350, and a Hall sensor 351;
  • Rotor assembly 400 rotor overmolding part 410, rotor overmolding part 410, first retaining ring 411, heat dissipation blade 412, inner sleeve 413, diversion hole 414, bearing seat 420, yoke 430, permanent magnet 440;
  • Gear assembly 500 sun gear 510 , planetary gear 520 , planet carrier 530 , and outer ring gear 540 .
  • orientation descriptions such as the orientation or positional relationship indicated by up, down, front, back, left, right, etc., are based on the orientation or positional relationship shown in the drawings, and only In order to facilitate the description of the present disclosure and simplify the description, it does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation, and thus should not be construed as limiting the present disclosure.
  • electric vehicles use in-wheel motors as power components, and the outer rotor and rim of the in-wheel motors are integrated into one structure, while in-wheel motors are designed to integrate the power system, transmission system and braking system into one.
  • the Hall sensor is used to sense the magnetic field of the permanent magnet of the rotor assembly in the radial direction.
  • the Hall sensor is usually installed on the stator core, and the sensor needs to be installed in the stator core. Groove, and the Hall sensor is fixed in the installation groove by cold pressing or gluing process, but the sensor installation groove affects the performance of the motor to a certain extent, and the installation process of the Hall sensor is complicated, which needs to be improved.
  • the Hall sensor and the Hall board are connected by pins or hard wires. After the hub motor runs for a long time, the pins or hard wires of the Hall sensor are prone to breakage, which is one of the main failure problems of the hub motor of electric vehicles. , affecting the reliability of electric vehicles.
  • the embodiment of the second aspect of the present disclosure proposes an in-wheel motor applied to an electric vehicle.
  • the in-wheel motor includes a central shaft 100 , a housing assembly 200 connected to the central shaft 100 , a stator assembly 300 , and a rotor assembly 400
  • the gear assembly 500 the center shaft 100 is connected to the vehicle frame of the electric vehicle and serves as the installation basis
  • the housing assembly 200 includes the main housing 210, the auxiliary housing 220 and the rim 230, and the main housing 210 and the auxiliary housing 220 are separately arranged on The two ends of the rim 230, the main housing 210 and the auxiliary housing 220 are fixedly connected to the two ends of the rim 230 by screws, three bearings 110 are installed on the central axis 100, the main housing 210, the auxiliary housing 220 and the rotor assembly 400 They are connected to a bearing 110 and can rotate relative to the center shaft 100 .
  • the stator assembly 300 includes a winding 310 and a stator core 320 , the stator core 320 includes a yoke 322 and a plurality of teeth 321 without tooth shoes, and the winding 310 is connected to the teeth 321 .
  • the stator core 320 has a certain thickness and forms a closed yoke 322 , a plurality of teeth 321 are evenly distributed along the circumferential direction of the yoke 322 , and the teeth 321 are straight teeth, which are convenient for loading into the winding 310 .
  • the stator core 320 is generally cut from silicon steel sheets, and the cut silicon steel sheets are processed into coiled stator cores 320.
  • the tooth part 321 of the stator core 320 is provided with a tooth shoe, when cutting the stator core, it is necessary to design the cutting method according to the tooth shoe, but no matter how optimized, in the case of the tooth shoe, silicon steel
  • the material utilization rate of the chip can only reach 70% at most, and it is difficult to further improve it.
  • the stator core 320 in the embodiment of the present disclosure adopts the tooth portion 321 without a tooth shoe, which optimizes the material cutting method, thereby improving the material utilization rate of the silicon steel sheet.
  • the tooth portion 321 is set in a straight tooth shape, the winding 310 does not need to be wound on the tooth portion 321, and the winding can be completed externally with a tooling, the operation space is large, and the full rate of the winding slot can be effectively improved.
  • the winding 310 adopts an aluminum wire with a non-circular cross-section, such as a rectangular, square or waist-circular aluminum wire, and the tooth part 321 adopts a straight-toothed structure.
  • the cross-section of the tooth part 321 is also a square.
  • the wire matches the shape of the tooth portion 321, and the aluminum wire is closely attached to the outer wall of the tooth portion 321, so that the arrangement of the aluminum wire is more compact, thereby improving the winding slot filling rate of the stator assembly 300, and the volume of the stator assembly 300 is small. Under changing conditions, the power density and efficiency of the in-wheel motor are improved.
  • the in-wheel motor is applied to electric vehicles, which helps to improve the battery life of electric vehicles.
  • the embodiment of the first aspect of the present disclosure proposes a stator assembly 300 applied to an in-wheel motor.
  • the stator core 320 of the stator assembly 300 is connected with a stator bracket 330 , and the stator bracket 330 is installed on the yoke 322
  • the stator bracket 330 and the stator core 320 are fixed as a whole
  • the middle part of the stator bracket 330 is provided with a bushing 331
  • the bushing 331 is fixed on the central shaft 100 to realize the positioning of the rotor assembly 300 .
  • a support bracket 340 is installed on the stator bracket 330, and at least one Hall plate mounting frame 341 is arranged around the support bracket 340.
  • the Hall plate mounting frame 341 is used to install the Hall plate 350, and at least one The Hall sensor 351, in the radial direction of the central axis 100, the Hall sensor 351 corresponds to the position of the permanent magnet 440 of the rotor assembly 400, as shown in Figure 1, the permanent magnet 440 is located outside the winding 310, and the Hall sensor 351 is also located in the winding On the outside of 310, the Hall sensor 351 is used to sense the magnetic field at the end of the permanent magnet 440 to determine the position of the permanent magnet 440, which helps to accurately control the operation of the hub motor.
  • the stator assembly 300 has a support bracket 340, the support bracket 340 installs the Hall plate 350 through the Hall plate mounting frame 341, the Hall sensor 351 is arranged on the Hall plate 350, and the fixed installation of the Hall sensor 351 is simpler and easier to operate , improve assembly efficiency; the stator assembly 300 uses the Hall plate 350 to install the Hall sensor 351, eliminating the need to set up a sensor installation slot in the stator core 320, avoiding affecting the electromagnetic performance of the stator assembly 300, and improving the performance of the in-wheel motor.
  • the Hall plate 350 has certain dimensions.
  • the support bracket 340 is provided with at least two Hall plate mounting frames 341. If two Hall plate mounting frames 341 are used, The two Hall plate mounting brackets 341 are connected to both ends of the Hall plate 350 to stably support the Hall plate 350 and prevent the Hall plate 350 from shifting or deforming.
  • the Hall plate 350 is an arc-shaped plate; each part of the stator assembly 300 corresponds to a Hall sensor 351, which is beneficial to drive the hub motor and make the starting torque of the hub motor larger.
  • Three Hall plate mounting frames 341 are arranged on the support bracket 340, and a Hall plate mounting frame 341 is respectively arranged at both ends and the middle of the Hall plate 350.
  • the three Hall plate mounting frames 341 are also arranged in an arc shape, corresponding to on the shape of the Hall plate 350.
  • Hall sensor 351 is connected to the Hall plate 350 using a chip structure, instead of pins or hard wires, which eliminates the problem of failure caused by broken pins or hard wires, and greatly improves the reliability and service life.
  • the Hall plate mounting frame 341 is provided with a first connecting piece 342, the first connecting piece 342 is used for fixedly connecting the Hall plate 350, and a mounting hole is set on the Hall plate 350 352 , the first connecting member 342 cooperates with the installation hole 352 to realize the fixing of the Hall plate installation frame 341 and the Hall plate 350 .
  • the first connecting member 342 is composed of four columns 3421, the four columns 3421 are uniformly distributed in the circumferential direction and form a columnar body, and the columnar body composed of the four columns 3421 can pass through the installation hole 352.
  • the stopper 3422 and the Hall plate mounting frame 341 cooperate to clamp the Hall plate 350, thereby realizing Fixed, the stopper 3422 prevents the first connecting piece 342 from coming out of the installation hole 352, improving the stability of use.
  • a guide slope is provided on the stopper 3422. During assembly, the edge of the installation hole 352 touches the guide slope, and the Hall plate 350 is pressed down to push the column 3421 to deform, and it is automatically loaded, which is simple and quick.
  • the cross sections of the four upright columns 3421 may be fan-shaped and cooperate to form a columnar body, or may have cross sections of other shapes and cooperate to form a columnar body.
  • the number of columns 3421 can also be two, three or more, which can also meet the requirement of fixing the Hall plate 350 .
  • first connecting member 342 can also use screws, pins, rivets, etc., which can also cooperate with the installation hole 352 to complete the fixing of the Hall plate 350 and meet the structural stability requirements.
  • the side on which the Hall plate mounting frame 341 is provided with the first connector 342 is defined as the front side, and the opposite side is the back side, and a rib 3411 is arranged on the back side, and the rib plate 3411 is arranged along the Hall plate mounting frame.
  • the length direction of 341 is arranged transversely.
  • the support bracket 340 is an injection molded part
  • the Hall plate mounting frame 341 and the rib 3411 are integrally injection molded, and the rib 3411 extends to the support bracket 340 .
  • the ribs 3411 are used to improve the structural strength and rigidity of the Hall plate mounting frame 341 , which is beneficial to stably support the Hall plate 350 .
  • the support bracket 340 is also provided with a plurality of second connecting pieces 343, the second connecting pieces 343 are used to connect the stator bracket 330, considering the stator bracket 330 is circular A plurality of second connecting pieces 343 are arranged in a circular ring along the circumferential direction of the support bracket 340 , and it is a better solution to use three second connecting pieces 343 evenly distributed in the circumferential direction.
  • the second connecting member 343 and the first connecting member 342 can adopt the same structure, for example, the second connecting member 343 is also composed of four uprights 3421, and the four uprights 3421 are uniformly distributed in the circumferential direction and form a cylinder shape, and the four uprights 3421
  • the upright post 3421 can pass through the through hole (not shown in the figure) on the stator bracket 330, and the end of the upright post 3421 is provided with a stopper 3422 protruding in the radial direction, and the stopper 3422 of the four upright post 3421 forms a retaining ring, After assembly, the stopper 3422 and the support bracket 340 cooperate to clamp the stator bracket 330, thereby realizing the fixation.
  • screws, pins, rivets, etc. can also be used for the second connecting member 343, which can also realize the function of fixedly connecting the stator bracket 330 and meet the requirement of structural stability.
  • a plurality of slot-crossing connecting wires 344 are arranged on the supporting bracket 340 , and the cross-slot connecting wires 344 are electrically connected to terminals of the winding 310 .
  • Multiple windings 310 are connected in series.
  • the terminal of the cross-slot connection wire 344 and the winding 310 can be fixed by welding, and the cross-slot connection wire 344 is located on a side away from the winding 310, which is convenient for welding.
  • the gear assembly 500 includes a sun gear 510, three planetary gears 520, a planetary carrier 530 and an outer ring gear 540, the sun gear 510 is fixedly connected to the rotor assembly 400, the planetary carrier 530 is fixedly connected to the center shaft 100, and the three planetary gears 520 is rotatably connected to the planet carrier 530, the outer ring gear 540 is fixedly connected to the main housing 210, the planetary gear 520 meshes with the sun gear 510 and the outer ring gear 540 at the same time, the rotor assembly 400 drives the sun gear 510 to rotate, and the sun gear 510 drives three The three planetary wheels 520 rotate, and the three planetary wheels 520 drive the outer ring gear 540 and the main housing 210 to rotate.
  • the main housing 210 drives the rim 230 to rotate.
  • the rim 230 belongs to the wheel of the electric vehicle, so the hub motor directly drives the wheel to rotate, realizing Driving of electric vehicles.
  • the planetary gear 520 is a double gear, and the planetary gear 520 realizes two-stage transmission deceleration, which reduces the speed of the rim 230 and increases the output torque of the hub motor, which is beneficial to the speed-up of the electric vehicle.
  • the gear assembly 500 is located between the rotor assembly 400 and the main casing 210, so the rotor assembly 400 and the main casing 210 cooperate to form a sealing grease cavity 201, the gear assembly 500 is arranged in the sealing grease cavity 201, and the sealing grease
  • the cavity 201 accommodates the gear assembly 500 on the one hand to prevent the gear assembly 500 from being exposed; lubrication to reduce wear.
  • a first retaining ring 411 is provided on the rotor assembly 400
  • a second retaining ring 211 is provided on the main housing 210
  • the first retaining ring 411 faces the main housing 210
  • the second retaining ring 211 faces the rotor assembly 400
  • the first retaining ring 411 and the second retaining ring 211 form the side wall of the grease sealing chamber 201 to prevent grease leakage.
  • the first retaining ring 411 and the second retaining ring 211 are arranged in a staggered manner, which can Block the grease that is flung away, promote the grease to stay in the grease chamber 201, and ensure that the gear assembly 500 has sufficient lubrication.
  • the first retaining ring 411 and the second retaining ring 211 are close to each other and There is no contact, and the independent rotation of the rotor assembly 400 and the main casing 210 is not affected.
  • the stator assembly of the hub motor pushes the rotor assembly 400 to rotate through electromagnetic force
  • the rotor assembly 400 drives the housing assembly 200 to rotate through the gear assembly 500
  • the housing assembly 200 drives the wheel of the electric vehicle to rotate through the rim 230 to realize electric car driving.
  • the gear assembly 500 is located in the grease chamber 201 between the rotor assembly 400 and the main housing 210.
  • Grease is stored in the grease chamber 201, and the grease is coated on the surface of the gear assembly 500 to provide lubrication.
  • the first part of the rotor assembly 400 The retaining ring 411 and the second retaining ring 211 of the main housing 210 are staggered in the axial direction to form a blocking structure, which can prevent the grease from being thrown out of the grease chamber 201, so that the grease stays in the grease chamber 201 to lubricate the gear assembly 500, improve the lubrication effect, avoid reliability problems such as wear and failure of the gear assembly 500 due to insufficient lubrication, improve the operation reliability of the hub motor, and improve the reliability of the electric vehicle.
  • the first retaining ring 411 and the second retaining ring 211 may not be staggered, and the two are flush, that is, the end surface of the first retaining ring 411 and the second retaining ring
  • the end faces of the ring 211 are located on the same plane, which can also block the grease that is thrown away, and encourage the grease to stay in the grease chamber 201 to ensure that the gear assembly 500 has sufficient lubrication.
  • the first retaining ring 411 is located outside the second retaining ring 211 , and the second retaining ring 211 is closer to the central shaft 100 .
  • the first retaining ring 411 After the grease is thrown away, it first contacts the second retaining ring 211, and then contacts the first retaining ring 411, and the first retaining ring 411 and the second retaining ring 211 are staggered, which can limit the grease that is thrown away, so that the lubrication Grease stays in the grease sealing chamber 201.
  • the main component of the rotor assembly 400 is the rotor overmolding part 410, the rotor overmolding part 410 wraps the yoke 430 and the permanent magnet 440 integrally during the injection molding process, and the bearing seat 420 and the rotor overmolding part 410 are also integrally formed.
  • the bearing housing 420 is located at the center of the rotor overmolding part 410.
  • the inner wall of the bearing housing 420 forms a bearing chamber to match the bearing 110.
  • the outer wall of the bearing housing 420 There are a plurality of bosses distributed in the circumferential direction.
  • the bosses are embedded in the rotor overmolding part 410, which improves the structural strength and facilitates the transmission of torque.
  • the rotor overmolding part 410 is an injection molded part
  • the first retaining ring 411 is arranged on the rotor overmolding part 410 to facilitate manufacturing and reduce costs.
  • the rotor assembly 400 adopts an integrated structure, and the rotor plastic package 410 is used to wrap the yoke 430 and the permanent magnet 440 to achieve fixation, to prevent the permanent magnet 440 from falling off, to improve the reliability of the rotor assembly 400, and to improve the service life of the in-wheel motor.
  • the rotor overmolding part 410 is provided with a plurality of heat dissipation fan blades 412, and the plurality of heat dissipation fan blades 412 are evenly distributed along the circumferential direction of the rotor overmolding part 410, and the rotor overmolding part 410 is provided with inner
  • the sleeve 413 and the bearing seat 420 are connected to the inner wall of the inner sleeve 413, and the cooling blades 412 radially extend from the outer wall of the inner sleeve 413.
  • the cooling blades 412 face the stator assembly 300 and dissipate heat
  • the height of the outer edge of the vane 412 is low to avoid the winding 310 of the stator assembly 300 .
  • a plurality of heat dissipation fan blades 412 are used to drive the airflow to take away the heat generated by the winding 310 to help cool down and prevent over-temperature shutdown.
  • the rotor overmolding part 410 is also provided with a plurality of guide holes 414, and the plurality of guide holes 414 are evenly distributed along the circumference of the rotor overmolding part 410, and each guide hole 414 Arranged between the extension lines of two adjacent cooling fan blades 412 , for example, the flow guide holes 414 may correspond to the cooling fan blades 412 one-to-one, or the number of flow guiding holes 414 may be half of the cooling fan blades 412 .
  • the rotor assembly 400 rotates at a high speed, and uses the heat dissipation blades 412 and the guide holes 414 to form an air circulation loop inside the hub motor, which improves the air convection capacity inside the hub motor, fully takes away the heat generated by the winding 310, and improves the performance of the hub motor. Excellent heat dissipation performance, reducing the temperature rise of the hub motor, so as to ensure the stability of the output efficiency of the hub motor and meet the load operation requirements of the hub motor.
  • the heat dissipation blades 412 also function as reinforcing ribs, which enhance the overall structural strength and rigidity of the rotor assembly 400 and improve reliability.
  • the first retaining ring 411 is integrally formed on the rotor overmolding part 410 , and a plurality of guide holes 414 are arranged on the outside of the first retaining ring 411 , the airflow flowing through the guide holes 414 It will not enter the grease sealing cavity 201, so as to prevent the air flow from affecting the grease.
  • the air guide hole 414 is located on the outer edge of the rotor overmolding part 410 , so that the airflow can quickly flow to contact the main casing 210 , which is beneficial for heat dissipation.
  • the distance between the winding 310 and the central axis 100 is substantially equal to the distance between the guide hole 414 and the central axis 100, and the positions of the two correspond, so that the heat dissipated by the winding 310 is absorbed
  • the airflow passing through the guide holes 414 is quickly taken away, which helps to improve the cooling effect of the winding 310 .
  • the distance between the permanent magnet 440 and the central axis 100 is approximately equal to the distance between the Hall sensor 351 and the central axis 100, and the position of the Hall sensor 351 corresponds to the position of the permanent magnet 440
  • the Hall sensor 351 is located outside the axial end of the permanent magnet 440.
  • the Hall sensor 351 is a magnetic field sensor capable of sensing the magnetic field at the end of the permanent magnet 440. The positions of the two correspond to improve reliability.
  • the Hall sensor 351 senses the magnetic field at the end of the permanent magnet 440, and its function is to detect the position of the magnetic pole of the permanent magnet 440 relative to the stator winding 300.
  • the induction information of the Hall sensor 351 can be input into the controller, and the controller can change the position at an appropriate time.
  • the current direction of the stator winding 310 can complete the commutation of the in-wheel motor and generate the required torque.
  • the rotation speed of the in-wheel motor can also be controlled through the induction information of the Hall sensor 351 .
  • the distance between the Hall sensor 351 and the permanent magnet 440 is defined as L, and it is set to 1mm ⁇ L ⁇ 4mm. Considering that the rotor assembly 400 rotates at a high speed when the hub motor is running, the Hall sensor 351 and the permanent magnet 440 A certain distance needs to be kept between the permanent magnets 440 to prevent the Hall sensor 351 from colliding with the rotor assembly 400. After testing, the distance between the Hall sensor 351 and the permanent magnet 440 is less than 1 mm, which is easy to rotate during the rotation of the rotor assembly 400.
  • the in-wheel motor proposed in the embodiment of the second aspect of the present disclosure includes the stator assembly 300 of the embodiment of the first aspect, includes all technical solutions of the stator assembly 300 , and has all the technical effects of the stator assembly 300 , so details will not be repeated one by one.
  • the electric vehicle proposed in the embodiment of the third aspect of the present disclosure includes the in-wheel motor in the embodiment of the second aspect, and the in-wheel motor includes a central shaft 100, a housing assembly 200 connected to the central shaft 100, a stator assembly 300, a stator assembly 300, and a gear assembly 500, the stator assembly 300 includes a winding 310, a stator core 320, and a support bracket 340, the support bracket 340 installs the Hall plate 350 through the Hall plate mounting bracket 341, the Hall sensor 351 is arranged on the Hall plate 350, and the Hall plate 350
  • the fixed installation of the sensor 351 is simpler, easy to operate, and improves assembly efficiency; the stator assembly 300 uses a Hall plate 350 to install the Hall sensor 351, eliminating the need to set up a sensor installation slot in the stator core 320, and avoiding affecting the electromagnetic performance of the stator assembly 300 , which is beneficial to improve the performance of the hub motor.

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  • Power Engineering (AREA)

Abstract

一种定子组件、轮毂电机及电动车，该定子组件(300)包括定子铁芯(320)、定子支架(330)、支撑托架(340)以及霍尔板(350)，定子铁芯(320)具有封闭的轭部，轭部的外周设置有多个齿部，齿部连接有绕组(310)，定子支架(330)固定连接于定子铁芯(320)，定子支架(330)位于轭部的内部，支撑托架(340)连接于定子支架(330)，支撑托架(340)设置有至少一个霍尔板安装架(341)，霍尔板(350)连接于霍尔板安装架(341)，霍尔板(350)连接有至少一个霍尔传感器(351)，沿定子铁芯(320)的径向，霍尔传感器(351)位于绕组(310)的外侧。

Description

定子组件、轮毂电机及电动车
相关申请的交叉引用
本申请要求于2021年12月16日提交的申请号为202111546612.7、名称为“定子组件、轮毂电机及电动车”，以及于2021年12月16日提交的申请号为202123196345.3、名称为“定子组件、轮毂电机及电动车”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本公开涉及电机技术领域，特别涉及一种定子组件、轮毂电机及电动车。
背景技术
相关技术中，在轮毂电机中设有霍尔传感器，霍尔传感器通常是安装在定子铁芯中，需要在定子铁芯中开设传感器安装槽，并通过冷压或胶粘工艺将霍尔传感器固定在安装槽中，霍尔传感器感在径向方向上感应转子组件的永磁体磁场。传感器安装槽在一定程度上影响电机的性能，且霍尔传感器安装工艺复杂，有待改进。
发明内容
本公开旨在至少解决现有技术中存在的技术问题之一。为此，本公开提出一种定子组件，霍尔传感器的安装工艺简单，有效提高霍尔传感器的可靠性。
本公开同时提出具有上述定子组件的轮毂电机。
本公开还提出具有上述轮毂电机的电动车。
根据本公开第一方面实施例的定子组件，包括定子铁芯、定子支架、支撑托架以及霍尔板，所述定子铁芯具有封闭的轭部，所述轭部的外周设置有多个齿部，所述齿部连接有绕组，所述定子支架固定连接于所述定子铁芯，所述定子支架位于所述轭部的内部，所述支撑托架连接于所述定子支架，所述支撑托架设置有至少一个霍尔板安装架，所述霍尔板连接于所述霍尔板安装架，所述霍尔板连接有至少一个霍尔传感器，沿所述定子铁芯的径向，所述霍尔传感器位于所述绕组的外侧。
根据本公开第一方面实施例的定子组件，至少具有如下有益效果：定子组件的定子支架连接有支撑托架，支撑托架通过霍尔板安装架安装霍尔板，霍尔传感器连接在霍尔板上，霍尔传感器位于所述绕组的外侧，对应于转子组件的永磁体，能够感应转子永磁体的轴向端部磁场；定子组件采用霍尔板安装霍尔传感器，免去在定子铁芯中开设传感器安装槽，防止影响定子组件的电磁性能，有利于提升轮毂电机的性能。
根据本公开第一方面的一些实施例，所述支撑托架设置有多个所述霍尔板安装架，多个所述霍尔板安装架沿所述支撑托架的周向间隔分布。
根据本公开第一方面的一些实施例，所述支撑托架设置有三个所述霍尔板安装架，所述霍尔板呈弧形并且连接三个所述霍尔板安装架。
根据本公开第一方面的一些实施例，所述霍尔板安装架设置有第一连接件，所述霍尔板设置有配合所述第一连接件的安装孔。
根据本公开第一方面的一些实施例，所述第一连接件包括多个立柱，多个所述立柱为周向分布，所述立柱的端部设置有挡块，所述挡块抵接于所述霍尔板。
根据本公开第一方面的一些实施例，所述霍尔板安装架设置有肋板，所述肋板与所述第一连接件布置在所述霍尔板安装架的两个相对面，所述肋板连接所述支撑托架。
根据本公开第一方面的一些实施例，所述支撑托架设置有多个第二连接件，多个所述第二连接件沿所述支撑托架的周向分布，所述第二连接件连接所述定子支架。
根据本公开第一方面的一些实施例，所述支撑托架设置有多个跨槽连接线，所述跨槽连接线电性连接所述绕组。
根据本公开第二方面实施例的轮毂电机，包含第一方面实施例的定子组件。
根据本公开第二方面的一些实施例，轮毂电机包括中轴，所述定子组件固定连接于所述中轴，所述中轴上通过轴承支撑有转子组件，所述转子组件具有永磁体，沿所述中轴的径向，所述霍尔传感器与所述永磁体位置对应。
根据本公开第二方面的一些实施例，沿所述中轴的轴向，所述霍尔传感器与所述永磁体之间的距离为L，满足1mm≤L≤4mm。
根据本公开第三方面实施例的电动车，包含第二方面实施例的轮毂电机。
本公开的附加方面和优点将在下面的描述中部分给出，部分将从下面的描述中变得明显，或通过本公开的实践了解到。
附图说明
本公开的附加方面和优点结合下面附图对实施例的描述中将变得明显和容易理解，其中：
图1为本公开第二方面实施例的轮毂电机的剖视图；
图2为本公开第一方面实施例的定子组件的结构示意图一；
图3为本公开第一方面实施例的定子组件的结构示意图二；
图4为本公开第一方面实施例中支撑托架和霍尔板的结构示意图一；
图5为本公开第一方面实施例中支撑托架和霍尔板的结构示意图二；
图6为本公开第一方面实施例中支撑托架的结构示意图；
图7为本公开第一方面实施例中支撑托架去除跨槽连接线的结构示意图一；
图8为本公开第一方面实施例中支撑托架去除跨槽连接线的结构示意图二；
图9为图7中的A处放大视图；
图10为本公开第二方面实施例中转子组件的结构示意图一；
图11为本公开第二方面实施例中转子组件的结构示意图二；以及
图12为本公开第二方面实施例中转子组件的分解示意图。
附图标号如下：
中轴100、轴承110；
壳体组件200、封脂腔201、主壳体210、第二挡圈211、副壳体220、轮辋230；
定子组件300、绕组310、定子铁芯320、齿部321、轭部322、定子支架330、轴套 331支撑托架340、霍尔板安装架341、肋板3411、第一连接件342、立柱3421、挡块3422、第二连接件343、跨槽连接线344、霍尔板350、霍尔传感器351；
转子组件400、转子包塑件410，转子包塑件410、第一挡圈411、散热风叶412、内套筒413、导流孔414、轴承座420、磁轭430、永磁体440；
齿轮组件500、太阳轮510、行星轮520、行星架530、外齿圈540。
具体实施方式
下面详细描述本公开的实施例，所述实施例的示例在附图中示出，其中自始至终相同或类似的标号表示相同或类似的元件或具有相同或类似功能的元件。下面通过参考附图描述的实施例是示例性的，仅用于解释本公开，而不能理解为对本公开的限制。
在本公开的描述中，需要理解的是，涉及到方位描述，例如上、下、前、后、左、右等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本公开和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本公开的限制。
在本公开的描述中，如果有描述到第一、第二只是用于区分技术特征为目的，而不能理解为指示或暗示相对重要性或者隐含指明所指示的技术特征的数量或者隐含指明所指示的技术特征的先后关系。
本公开的描述中，除非另有明确的限定，设置、安装、连接等词语应做广义理解，所属技术领域技术人员可以结合技术方案的具体内容合理确定上述词语在本公开中的具体含义。
相关技术中，电动车采用轮毂电机作为动力部件，轮毂电机的外转子和轮辋为一体结构，而轮毂电机在设计上追求动力系统、传动系统及刹车系统集成为一体。轮毂电机中设有霍尔传感器，霍尔传感器感用于在径向方向上感应转子组件的永磁体的磁场，霍尔传感器通常是安装在定子铁芯上，需要在定子铁芯中开设传感器安装槽，并通过冷压或胶粘工艺将霍尔传感器固定在安装槽中，但是传感器安装槽在一定程度上影响电机的性能，且霍尔传感器安装工艺复杂，有待改进。霍尔传感器和霍尔板之间通过针脚或硬线连接，在轮毂电机的长时间运行后，霍尔传感器的针脚或硬线容易发生断裂，这是电动车的轮毂电机主要的失效问题之一，影响电动车的使用可靠性。
如图1所示，本公开第二方面的实施例提出一种应用于电动车的轮毂电机，轮毂电机包括中轴100以及连接于中轴100的壳体组件200、定子组件300、转子组件400以及齿轮组件500，中轴100连接于电动车的车架并且作为安装基础，壳体组件200包括主壳体210、副壳体220以及轮辋230，主壳体210和副壳体220分置在轮辋230的两端，主壳体210和副壳体220通过螺丝固定连接在轮辋230的两端，中轴100上安装有三个轴承110，主壳体210、副壳体220以及转子组件400各连接于一个轴承110，均能相对中轴100转动。
参照图2和图3，定子组件300包括绕组310及定子铁芯320，定子铁芯320包括轭部322和多个无齿靴的齿部321，绕组310连接在齿部321上。定子铁芯320具有一定厚度并且形成封闭的轭部322，多个齿部321沿轭部322的周向均布，齿部321采用直齿，便于装入绕组310。
定子铁芯320一般采用硅钢片裁切而成，将裁切出的硅钢片加工成卷绕式的定子铁芯320，为了提高硅钢片的利用率，在裁切时需要提前设计拼料裁切方式，如果定子铁芯320的齿部321设置有齿靴，在切割定子铁芯时，必须要根据齿靴去设计拼料裁切方式，但是无论如何优化，在有齿靴的情况下，硅钢片的材料利用率最多也只能达70％，很难进一步提升。本公开实施例的定子铁芯320采用无齿靴的齿部321，优化拼料裁切方式，进而提高硅钢片的材料利用率。
可以理解的是，齿部321设置为直齿状，绕组310无须在齿部321上绕线，可以在外部利用工装完成绕线，操作空间大，能够有效提高绕线槽满率。此外，绕组310采用非圆形截面的铝导线，比如长方形、正方形或腰圆形截面的铝导线，而齿部321采用直齿形结构，比如齿部321的截面同样为正方形，绕组310的铝导线匹配齿部321的形状，铝导线紧密贴合在齿部321的外壁，使得铝导线的排布更为紧密，因而提高了定子组件300的绕线槽满率，在定子组件300的体积不变的情况下，提升了轮毂电机的功率密度和效率，轮毂电机应用于电动车，有助于提升电动车的续航能力。
参照图2和图3，本公开第一方面的实施例提出一种应用于轮毂电机的定子组件300，定子组件300的定子铁芯320连接有定子支架330，定子支架330安装在轭部322的内孔中，定子支架330与定子铁芯320固定为一体，定子支架330的中部设置有轴套331，轴套331固定在中轴100上，实现转子组件300的定位。定子支架330上安装有支撑托架340，支撑托架340的周边设置有至少一个霍尔板安装架341，霍尔板安装架341用于安装霍尔板350，霍尔板350上设置至少一个霍尔传感器351，在中轴100的径向上，霍尔传感器351与转子组件400的永磁体440位置对应，如图1所示，永磁体440位于绕组310的外侧，霍尔传感器351也位于绕组310的外侧，利用霍尔传感器351感应永磁体440端部的磁场，以确定永磁体440的位置，有助于准确控制轮毂电机的运转。
定子组件300具有支撑托架340，支撑托架340通过霍尔板安装架341安装霍尔板350，霍尔传感器351设置在霍尔板350上，霍尔传感器351的固定安装更简单，便于操作，提高组装效率；定子组件300采用霍尔板350安装霍尔传感器351，免去在定子铁芯320中开设传感器安装槽，避免影响定子组件300的电磁性能，有利于提升轮毂电机的性能。
可以理解的是，霍尔板350具有一定的外形尺寸，为了稳定支撑霍尔板350，支撑托架340设置有至少两个霍尔板安装架341，若采用两个霍尔板安装架341，则两个霍尔板安装架341连接在霍尔板350的两端，以稳定支撑霍尔板350，防止霍尔板350移位或者变形。
参照图5，可以理解的是，考虑到转子组件400是旋转的圆形部件，霍尔板350上设有三个霍尔传感器351，三个霍尔传感器351应当布置为圆弧形，以感应旋转的永磁体440的磁场，对应的，霍尔板350为弧形板件；定子组件300的每相对应一个霍尔传感器351，利于驱动轮毂电机，使轮毂电机的起步力矩更大。在支撑托架340上设置三个霍尔板安装架341，霍尔板350的两端和中部各布置一个霍尔板安装架341，三个霍尔板安装架341同样呈弧形布置，对应于霍尔板350的形状。
可以理解的是，霍尔传感器351采用贴片式结构连接在霍尔板350上，代替针脚或硬线连接，消除了针脚或硬线断裂导致失效的问题，大大提高使用可靠性及使用寿命。
参照图4至图7，可以理解的是，霍尔板安装架341上设置有第一连接件342，第一 连接件342用于固定连接霍尔板350，在霍尔板350上设置安装孔352，第一连接件342与安装孔352配合，实现霍尔板安装架341与霍尔板350的固定。
参照图9，可以理解的是，第一连接件342由四个立柱3421构成，四个立柱3421周向均布并形成柱状体，四个立柱3421组成的柱状体能够穿过安装孔352，在立柱3421的端部设置有沿径向凸出的挡块3422，四个立柱3421的挡块3422形成挡圈，组装后，挡块3422和霍尔板安装架341配合夹住霍尔板350，从而实现固定，挡块3422防止第一连接件342从安装孔352中脱出，提高使用稳定性。为了便于组装，在挡块3422上设置导向斜面，组装时，安装孔352的边缘抵接导向斜面，压下霍尔板350推动立柱3421变形，自动装入，简单快捷。
可以理解的是，四个立柱3421的截面可以是扇形，配合组成柱状体，也可以是其他形状的截面，配合组成柱状体。立柱3421的数量也可以是两个、三个或者更多，同样能够满足固定霍尔板350。
可以理解的是，第一连接件342还可以采用螺丝、销钉、铆钉等，同样能够配合安装孔352完成对霍尔板350的固定，满足结构稳定性要求。
参照图7和图8，将霍尔板安装架341设置第一连接件342的侧面定义为正面，则相对面为背面，在背面上设置有肋板3411，肋板3411沿霍尔板安装架341的长度方向横贯布置，考虑到支撑托架340为注塑件，一体注塑成型霍尔板安装架341及肋板3411，肋板3411延伸至支撑托架340。利用肋板3411提高霍尔板安装架341的结构强度和刚度，有利于稳定支撑霍尔板350。
参照图3、图5和图8，可以理解的是，支撑托架340还设置有多个第二连接件343，第二连接件343用于连接定子支架330，考虑到定子支架330为圆形，多个第二连接件343沿支撑托架340的周向布置为一个圆环，其中采用三个周向均布的第二连接件343为较佳方案。
可以理解的是，第二连接件343与第一连接件342可以采用同样的结构，比如第二连接件343同样由四个立柱3421构成，四个立柱3421周向均布并形成柱体状，四个立柱3421能够穿过定子支架330上的通孔(图中未示出)，在立柱3421的端部设置有沿径向凸出的挡块3422，四个立柱3421的挡块3422形成挡圈，组装后，挡块3422和支撑托架340配合夹住定子支架330，从而实现固定。
当然，第二连接件343也可以采用螺丝、销钉、铆钉等，同样能够实现固定连接定子支架330的功能，满足结构稳定性要求。
参照图2和图4，可以理解的是，支撑托架340上布置有多个跨槽连接线344，跨槽连接线344电性连接绕组310的接线端，利用多个跨槽连接线344实现串联多个接绕组310。跨槽连接线344与绕组310的接线端可采用焊接固定，跨槽连接线344位于背离绕组310的一侧，便于进行焊接。
参照图1，齿轮组件500包括太阳轮510、三个行星轮520、行星架530以及外齿圈540，太阳轮510固定连接于转子组件400，行星架530固定连接中轴100，三个行星轮520转动连接在行星架530上，外齿圈540固定连接于主壳体210，行星轮520同时啮合于太阳轮510、外齿圈540，转子组件400带动太阳轮510旋转，太阳轮510驱动三个行星轮520旋转，三个行星轮520再驱动外齿圈540与主壳体210旋转，主壳体210带动轮辋230 旋转，轮辋230属于电动车的车轮，因此轮毂电机直接驱动车轮转动，实现电动车的行驶。此外，行星轮520为双联齿轮，通过行星轮520实现了两级的传动减速，降低了轮辋230的转速，同时提升轮毂电机的输出扭矩，有利于电动车提速。
可以理解的是，齿轮组件500位于转子组件400和主壳体210之间，因此转子组件400和主壳体210配合组成一个封脂腔201，齿轮组件500设在封脂腔201内，封脂腔201一方面是容纳齿轮组件500，防止齿轮组件500外露，另一方面是容置润滑脂，使得太阳轮510、三个行星轮520以及外齿圈540的表面能够涂覆润滑脂，提供充足的润滑，减少磨损。
可以理解的是，考虑到在太阳轮510和三个行星轮520高速旋转中，由于离心力的作用会将润滑脂甩离，进而导致太阳轮510和三个行星轮520出现润滑不足的问题，因此在转子组件400上设置第一挡圈411，主壳体210上设置第二挡圈211，第一挡圈411朝向主壳体210，第二挡圈211朝向转子组件400，第一挡圈411和第二挡圈211组成封脂腔201的侧壁，起到防止润滑脂外漏的作用，在中轴100的轴向上，第一挡圈411和第二挡圈211为交错布置，能够阻挡被甩离的润滑脂，促使润滑脂留在封脂腔201内，保证齿轮组件500具有充足的润滑，在中轴100的径向上，第一挡圈411和第二挡圈211相互靠近而且不接触，不影响转子组件400和主壳体210各自的独立转动。轮毂电机运行时，轮毂电机的定子组件通过电磁力作用推动转子组件400旋转，转子组件400通过齿轮组件500驱动壳体组件200旋转，壳体组件200通过轮辋230带动电动车的车轮转动，实现电动车的行驶。齿轮组件500位于转子组件400与主壳体210之间的封脂腔201内，封脂腔201内储存润滑脂，润滑脂涂覆在齿轮组件500的表面以提供润滑，转子组件400的第一挡圈411与主壳体210的第二挡圈211在轴向上交错，形成阻挡结构，能够防止润滑脂被甩出封脂腔201，使得润滑脂留在封脂腔201内以润滑齿轮组件500，提升润滑效果，避免齿轮组件500因润滑不足而发生磨损、失效等可靠性问题，提高轮毂电机的运行可靠性，提高电动车的使用可靠性。
可以理解的是，在中轴100的轴向上，第一挡圈411和第二挡圈211也可以不交错，两者为齐平布置，也即第一挡圈411的端面和第二挡圈211的端面位于同一平面，也能够阻挡被甩离的润滑脂，促使润滑脂留在封脂腔201内，保证齿轮组件500具有充足的润滑。
参照图1，可以理解的是，在中轴100的径向上，第一挡圈411位于第二挡圈211的外侧，第二挡圈211更加靠近中轴100。润滑脂被甩离后，先接触第二挡圈211，再接触第一挡圈411，而且第一挡圈411与第二挡圈211是交错的，能够限制被甩离的润滑脂，使得润滑脂留在封脂腔201内。
参照图10至图12，可以理解的是，转子组件400的主要构件是转子包塑件410，转子包塑件410通过在注塑成型的过程中一体包裹磁轭430及永磁体440，而且轴承座420与转子包塑件410也是一体成型的结构，轴承座420位于转子包塑件410的中心，轴承座420的内壁形成轴承室以配合轴承110，为了提高连结的稳固性，轴承座420的外壁具有多个周向分布的凸台，在注塑成型后，凸台嵌入转子包塑件410内，提高结构强度，而且有利于传递扭矩。考虑到转子包塑件410是注塑件，将第一挡圈411设置在转子包塑件410上，便于制造，降低成本。转子组件400采用一体化的结构，利用转子包塑件410包裹磁轭430及永磁体440实现固定，避免永磁体440脱落，提升转子组件400的可靠性，有利 于提高轮毂电机的使用寿命。
参照图1和图6，可以理解的是，转子包塑件410设置有多个散热风叶412，多个散热风叶412沿转子包塑件410的周向均布，转子包塑件410设置有内套筒413，轴承座420连接在内套筒413的内壁，散热风叶412从内套筒413的外壁径向延伸，在轮毂电机的内部，散热风叶412是朝向定子组件300的，而且散热风叶412的外边缘高度较低，以避让定子组件300的绕组310。当转子组件400高速旋转，利用多个散热风叶412驱动气流流动，从而带走绕组310产生的热量，帮助降温，防止出现超温停机的问题。
参照图6至图8，可以理解的是，转子包塑件410上还设置有多个导流孔414，多个导流孔414沿转子包塑件410的周向均布，每个导流孔414布置在两个相邻的散热风叶412的延长线之间，比如可以是导流孔414与散热风叶412一一对应，也可以是导流孔414的数量为散热风叶412的一半。如图1所示，转子组件400高速旋转时，利用多个散热风叶412驱动气流流动，导流孔414作为气流流动的通道，连通了转子包塑件410的两侧，气流流动至壳体组件200的内腔，壳体组件200的主壳体210和副壳体220为金属件，比如铝合金制件，具有较大的结构强度和优良的传热性能，气流接触主壳体210和副壳体220，并且通过主壳体210和副壳体220将热量散发到外部空间。
转子组件400高速旋转，利用散热风叶412和导流孔414在轮毂电机的内部形成气流循环回路，提升了轮毂电机内部的空气对流能力，充分将绕组310产生的热量带走，提升了轮毂电机的散热性能，降低轮毂电机的温升，从而保证轮毂电机的输出效率稳定，满足轮毂电机的带负载运行需求。此外，散热风叶412还具备加强筋的作用，提升了转子组件400整体的结构强度和刚度，提高可靠性。
参照图11，可以理解的是，第一挡圈411一体成型在转子包塑件410上，而且多个导流孔414布置在第一挡圈411的外侧，从导流孔414中流过的气流不会进入封脂腔201，避免气流影响润滑脂。而且，导流孔414位于转子包塑件410的外边缘，气流能够快速流动至接触主壳体210，有利于散热。
参照图1，可以理解的是，在中轴100的径向上，绕组310与中轴100的距离基本等于导流孔414与中轴100的距离，两者位置对应，使得绕组310散发的热量被经过导流孔414的气流快速带走，有助于提升绕组310的散热效果。
参照图1，可以理解的是，在中轴100的径向上，永磁体440与中轴100的距离大致等于霍尔传感器351与中轴100的距离，霍尔传感器351与永磁体440的位置对应，转子组件400旋转时，霍尔传感器351位于永磁体440的轴向端部外侧，霍尔传感器351是一个磁场传感器，能够感应永磁体440端部的磁场，两者位置对应，提升可靠性。霍尔传感器351感应永磁体440端部的磁场，作用是检测永磁体440的磁极相对于定子绕组300的位置，霍尔传感器351的感应信息可以输入到控制器中，通过控制器在恰当时间改变定子绕组310的电流方向，能够完成轮毂电机的换相，产生需要的转矩。此外，还可以通过霍尔传感器351的感应信息控制轮毂电机的转速。
可以理解的是，将霍尔传感器351与永磁体440之间的距离定义为L，设定1mm≤L≤4mm，考虑到轮毂电机运转时，转子组件400是高速旋转的，霍尔传感器351与永磁体440之间需要保持一定的距离，防止霍尔传感器351碰撞到转子组件400，经过试验，霍尔传感器351与永磁体440之间的间距范围小于1mm，在转子组件400的旋转过程中容易发生 碰撞摩擦，安全距离不足，因此设定1mm≤L；当霍尔传感器351与永磁体440之间的间距大于4mm，则霍尔传感器351能够感应到的永磁体440端部的磁场过小，霍尔传感器351无法准确检测永磁体440的位置，因此设定L≤4mm，其中L的取值在2mm至3mm为较佳方案。
本公开第二方面实施例提出的轮毂电机，包含第一方面实施例的定子组件300，包含定子组件300的全部技术方案，具有定子组件300的全部技术效果，不再一一赘述。
本公开第三方面实施例提出的电动车，包含第二方面实施例的轮毂电机，轮毂电机包括中轴100以及连接于中轴100的壳体组件200、定子组件300、定子组件300以及齿轮组件500，定子组件300包括绕组310、定子铁芯320以及支撑托架340，支撑托架340通过霍尔板安装架341安装霍尔板350，霍尔传感器351设置在霍尔板350上，霍尔传感器351的固定安装更简单，便于操作，提高组装效率；定子组件300采用霍尔板350安装霍尔传感器351，免去在定子铁芯320中开设传感器安装槽，避免影响定子组件300的电磁性能，有利于提升轮毂电机的性能。
上面结合附图对本公开实施例作了详细说明，但是本公开不限于上述实施例，在所属技术领域普通技术人员所具备的知识范围内，还可以在不脱离本公开宗旨的前提下，作出各种变化。

Claims (12)

  1. 定子组件，包括：
    定子铁芯，具有封闭的轭部，所述轭部的外周设置有多个齿部；
    绕组，连接于所述齿部；
    定子支架，连接于所述定子铁芯，所述定子支架位于所述轭部的内部；
    支撑托架，连接于所述定子支架，所述支撑托架设置有至少一个霍尔板安装架；
    霍尔板，连接于所述霍尔板安装架；以及
    至少一个霍尔传感器，连接于所述霍尔板，沿所述定子铁芯的径向，所述霍尔传感器位于所述绕组的外侧。
  2. 根据权利要求1所述的定子组件，其中，所述支撑托架设置有多个所述霍尔板安装架，多个所述霍尔板安装架沿所述支撑托架的周向间隔分布。
  3. 根据权利要求2所述的定子组件，其中，所述支撑托架设置有三个所述霍尔板安装架，所述霍尔板呈弧形并且连接三个所述霍尔板安装架。
  4. 根据权利要求1至3中任一项所述的定子组件，其中，所述霍尔板安装架设置有第一连接件，所述霍尔板设置有配合所述第一连接件的安装孔。
  5. 根据权利要求4所述的定子组件，其中，所述第一连接件包括多个立柱，多个所述立柱为周向分布，所述立柱的端部设置有挡块，所述挡块抵接于所述霍尔板。
  6. 根据权利要求4所述的定子组件，其中，所述霍尔板安装架设置有肋板，所述肋板与所述第一连接件布置在所述霍尔板安装架的两个相对面，所述肋板连接所述支撑托架。
  7. 根据权利要求4所述的定子组件，其中，所述支撑托架设置有多个第二连接件，多个所述第二连接件沿所述支撑托架的周向分布，所述第二连接件连接所述定子支架。
  8. 根据权利要求1所述的定子组件，其中，所述支撑托架设置有多个跨槽连接线，所述跨槽连接线电性连接所述绕组。
  9. 轮毂电机，包含如权利要求1至8中任一项所述的定子组件。
  10. 根据权利要求9所述的轮毂电机，还包括中轴，其中所述定子组件固定连接于所述中轴，所述中轴上通过轴承支撑有转子组件，所述转子组件具有永磁体，沿所述中轴的径向，所述霍尔传感器与所述永磁体位置对应。
  11. 根据权利要求10所述的轮毂电机，其中，沿所述中轴的轴向，所述霍尔传感器与所述永磁体之间的距离为L，满足1mm≤L≤4mm。
  12. 电动车，包含如权利要求9至11中任一项所述的轮毂电机。
PCT/CN2022/079099 2021-12-16 2022-03-03 定子组件、轮毂电机及电动车 WO2023108918A1 (zh)

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JP2017070072A (ja) * 2015-09-29 2017-04-06 本田技研工業株式会社 アウターロータ型回転電機
CN108462327A (zh) * 2018-02-02 2018-08-28 卧龙电气集团股份有限公司 一种霍尔线路板固定结构
CN208272827U (zh) * 2018-03-07 2018-12-21 广东美的生活电器制造有限公司 霍尔传感器组件和具有其的电机以及食品料理机
CN210608882U (zh) * 2019-09-27 2020-05-22 深圳拓邦股份有限公司 一种直流无刷电机

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Publication number Priority date Publication date Assignee Title
JP2017070072A (ja) * 2015-09-29 2017-04-06 本田技研工業株式会社 アウターロータ型回転電機
CN108462327A (zh) * 2018-02-02 2018-08-28 卧龙电气集团股份有限公司 一种霍尔线路板固定结构
CN208272827U (zh) * 2018-03-07 2018-12-21 广东美的生活电器制造有限公司 霍尔传感器组件和具有其的电机以及食品料理机
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