An Axial Flux Hub Motor

The present utility model relates to an axial flux hub motor that includes a hub, a rotor, a stator, and a central shaft. The central shaft runs through the hub, rotor, and stator. The stator connects firmly to the central shaft, while the rotor and hub rotate around it. The rotor contains multiple magnetic steel plates to generate axial magnetic flux. Meanwhile, the stator uses a positioning plate and several stator cores. These stator cores sit on the positioning plate, and the windings wrap directly around them to form the electromagnetic structure. In addition, the positioning plate includes an installation opening, and one end of each stator core fits into this opening for accurate alignment and stable mounting.

Compared with the prior art, the present utility model features multiple stator cores for enhanced magnetic permeability and improved ventilation cooling. Furthermore, each stator core is independently mounted on the positioning plate, facilitating disassembly and maintenance while reducing maintenance costs.

Technical Field

The present utility model relates to an axial flux hub motor, falling within the technical field of hub motors.

Background Technology

As a core component in electric vehicles, the performance of hub motors directly affects the overall performance of the vehicle. However, most electric vehicle hub motors still use a traditional radial-field outer-rotor structure, which often fails to meet modern range requirements.

To overcome these limitations, various technical improvements have been proposed, and several have already been patented. For example, Chinese Patent Publication (Application No. 202010002588.X, Publication No. CN111009996A) discloses a hub motor comprising a hub, rotor, stator, and central shaft. In this design, the stator includes a bracket and a stator disc integrally bonded to the outside of the bracket. The disc is formed by encapsulating the windings with potting compound. Although this approach simplifies certain processes, it completely removes the stator core. As a result, the motor shows poor magnetic permeability, a larger equivalent air-gap length, and increased consumption of permanent-magnet material compared with iron-core motors. Consequently, both motor performance and cost efficiency are negatively affected.

In addition, existing iron-core axial flux wheel motors usually integrate the stator core and positioning plate into a single molded structure. This configuration complicates the winding process and makes maintenance more difficult. When a failure occurs, the user must disassemble and replace the entire stator assembly, which leads to high repair difficulty and significantly higher maintenance costs.

High-efficiency axial flux hub motor with laminated stator core and multi-pole rotor design

Content

This utility model aims to solve several problems found in existing axial flux hub motors. Many current designs show low magnetic permeability and are difficult to disassemble during maintenance. To overcome these shortcomings, this utility model introduces a motor structure that improves magnetic performance and simplifies servicing.

To achieve this goal, the proposed axial flux hub motor includes a hub, rotor, stator, and central shaft. The central shaft runs through the hub, rotor, and stator. The stator connects firmly to the central shaft, while the hub and rotor rotate around it. The rotor contains multiple magnetic steel plates. The stator includes a positioning plate and several stator cores. These stator cores sit on the positioning plate, and windings wrap around each core.

Detailed Implementation

The following section describes the utility model with reference to Figures 1–5. The axial flux hub motor consists of a hub 1, rotor 2, stator 3, and central shaft 4. The central shaft 4 passes through the hub 1, rotor 2, and stator 3. The stator 3 fastens securely to the central shaft 4. In contrast, the hub 1 and rotor 2 rotate around the shaft during motor operation.

The rotor 2 carries multiple magnetic steel plates 21. These plates generate axial magnetic flux as the rotor turns. The stator 3 includes a stator core 31 and a positioning plate 32. The stator core 31 mounts onto the positioning plate 32, and windings 33 wrap tightly around the stator core 31.

The stator core uses laminated silicon steel sheets. These sheets stack perpendicular to the axial direction, which increases magnetic permeability and reduces energy loss. Furthermore, the laminated structure enhances ventilation and improves cooling efficiency during operation.

Axial flux hub motor with high torque density and compact stator core design