CN106208545A - Amorphous alloy core body permanent-magnet brushless DC electric machine - Google Patents

Amorphous alloy core body permanent-magnet brushless DC electric machine Download PDF

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Publication number
CN106208545A
CN106208545A CN201610818648.9A CN201610818648A CN106208545A CN 106208545 A CN106208545 A CN 106208545A CN 201610818648 A CN201610818648 A CN 201610818648A CN 106208545 A CN106208545 A CN 106208545A
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motor
hall element
core body
aluminum metal
permanent
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CN106208545B (en
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彭希南
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Guangdong Lianbai Technology Group Co ltd
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    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K29/00Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices
    • H02K29/06Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices with position sensing devices
    • H02K29/08Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices with position sensing devices using magnetic effect devices, e.g. Hall-plates, magneto-resistors
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K3/00Details of windings
    • H02K3/02Windings characterised by the conductor material
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K5/00Casings; Enclosures; Supports
    • H02K5/04Casings or enclosures characterised by the shape, form or construction thereof

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Brushless Motors (AREA)

Abstract

nullA kind of amorphous alloy core body permanent-magnet brushless DC electric machine,It is made up of motor body and controller two parts,Motor body part includes motor upper cover、Motor bottom end cover、Motor output shaft、Axle sleeve、Upper skeleton、Lower skeleton、Stator coil、Stator core body、Rotor core body、Nd-Fe-B permanent magnetic block,Controller part includes aluminum metal-matrix printed substrate、Control cable,Double-core single-chip microcomputer、Power VMOS tube、Hall element,It is characterized by: described stator core body and and rotor core body be formed by stacking by Fe-based amorphous alloy sheet,Stator core body is supported fixing by upper skeleton and lower skeleton jointly,Stator coil oxygen-free copper-wire coiling,Described controller component and circuit are fully integrated on aluminum metal-matrix printed substrate,External screw thread has been engraved on the support aluminum metal cylinder of aluminum metal-matrix printed substrate,Screwed in during installation in the inner thread in motor bottom end cover,Form motor body and controller electromechanical integrated structure.

Description

Amorphous alloy core body permanent-magnet brushless DC electric machine
Technical field
The amorphous alloy core body permanent-magnet brushless DC electric machine that the present invention relates to, is a kind of high power density and high efficiency Brshless DC motor, is mainly used in space flight and aviation, New-energy electric vehicle, all kinds of high end home electrical equipment and Industry Control and drives neck Territory.
Background technology
Since 1978, it is brushless directly that Mannasman company of former West Germany is proposed first square wave on Hanover's trade fair Since stream motor and driver thereof, permanent-magnet brushless DC electric machine has been achieved for considerable entering in manufacture and control technical elements Step, and it is widely used in DC frequency converting air-conditioner, household electrical appliance, electric automobile, battery-operated motor cycle, hybrid vehicle, electricity Dynamic yacht, space flight and aviation and all types of industries buncher control field.But, it is effective that current permanent-magnet brushless DC electric machine manufactures Material such as electrical sheet, conductive material the most still follow traditional stalloy and enamel-covered wire, so, existing DC permanent-magnetic brushless The energy-saving and cost-reducing space that still has greatly improved of motor, the Energy Efficiency Ratio of motor and power density need to improve further.Another Aspect, permanent-magnet brushless DC electric machine is being installed and in control model, is all being used motor body and controller independence divided mode, lead Causing existing permanent-magnet brushless DC electric machine all inconvenient on using, mainly permanent-magnet brushless DC electric machine can not be used alone, It must coordinate with controller and could normally work, and there are many numerous and diverse between permanent-magnet brushless DC electric machine and controller Control line, use identification to get up and bother very much, and the reliability that connecting line uses connector is also had a greatly reduced quality.Along with new energy Source electric car in the ascendant, the development of Power Electronic Technique and the raising of whole world energy-saving and emission-reduction consciousness, develop efficiently joint Can type permanent-magnet brushless DC electric machine be trend of the times.
Obviously, the usefulness quality of permanent-magnet brushless DC electric machine to be promoted should take multi-pronged measure: first, performance Improve and be unable to do without high-performance conductive material and the application of permeability magnetic material;Next to that permanent-magnet brushless DC electric machine needs on the topology There is great strategic structural, the integral structure of motor body and controller could be realized;The more important thing is, DC permanent-magnetic brushless Motor and control system, as electromechanical integrated product, belong to the product that electromechanics combines, and therefore, most important innovation is still electricity Machine and the system integration and the technological synthesis that control parts.Visible, the high-efficiency energy-saving technology of permanent-magnet brushless DC electric machine, brand-new opening up Flutter structure design and intelligentized reliable control be still the focus of current permanent-magnet brushless DC electric machine research, be also permanent magnetism without The innovation and development direction that brushless motor is important.
Summary of the invention
Technical problem
In order to develop energy-efficient permanent-magnet brushless DC electric machine, say from the material used, first should be from traditional selection The traditional mode selected materials is come out of.At present, traditional permanent-magnet brushless DC electric machine stator winding still uses common enamel-covered wire, and The PWM high-frequency modulation signal of Controller for PM DC Brushless Motor output is at least motor and runs about 10 times of highest frequency, Common enamel-covered wire kelvin effect under the big electric current of high frequency is obvious, and in the case of high-power, copper loss and heating are the most prominent.According to This, it is thus proposed that use superconductor to reduce the scheme of copper olse, but, the high-critical temperature of present superconductor is 150K, i.e.-123 DEG C, the superconductor worked under ultralow temperature is obviously not suitable for popularization and application.
On the other hand, the used material of stator core is mainly traditional stalloy, due to the change of magnetic flux in stator core Change frequency to be directly proportional to the rotating speed of motor, and specific loss consumption is proportional to the 1.3 of frequency~1.5 powers, so stalloy group Rising along with frequency is dramatically increased by the loss becoming stator core.According to measuring and calculating, frequency be 50Hz, magnetic flux density be Under 1.0 T, the loss of silicon steel stator core is less, only 1.4W/kg, and along with the rising of frequency, the loss of stator core is the biggest Amplitude raises.When frequency be increased to 1 kHz, magnetic flux density be 1.0 T time, the loss of silicon steel stator core increase to 102W/ kg.Such as, a rotating speed is the motor of 60000r/min, when stator core changes of magnetic field frequency is 3000 r/min, motor Unit iron loss will increase by 50~80 times, for reducing high-frequency loss unshakable in one's determination, can use the magnetic flux density or employing reduced in iron core The method of low-loss core material.
From a structural point, existing permanent-magnet brushless DC electric machine at least should carry out significant improvement in terms of four: one It is to change motor body in frame for movement to separate the present situation of use with controller, it is achieved permanent-magnet brushless DC electric machine and controller Integral structure, fully phases out line between the two, strengthens its ease for use, and this is also necessarily sending out of permanent-magnet brushless DC electric machine Exhibition trend;Two is single-chip microcomputer rather than the DSP using efficient double-core on circuit topological structure, both can ensure in speed that motor is high Speed is operating the most effectively to be controlled, and can be substantially reduced again device cost simultaneously;Three is to change to use in heat radiation topological structure to pass The traditional design of system FR4 printed substrate, by using the printed substrate of high duty metal base, improves external conduction of heat Rate, it is not necessary to fan, directly reduces the heat sink temperature of high-power V metal-oxide-semiconductor;Four is to change hall position sensor to pass through manual setting Assembling is embedded in the custom of winding unshakable in one's determination, is directly welded on the printed substrate of Metal Substrate, and this is to simplify brushless, permanently Direct current generator production technology, improves Hall orientation sensing accuracy and the preferable measure of production efficiency.
Obviously, after motor body and controller unite two into one, the most derivative problem made new advances: is how to allow motor originally The effective combination on space structure is realized between body and controller;Two is how to dispose both integrated rear serious heat radiations to ask Topic;Three be by what method realize energy-saving and cost-reducing to reach system and save most, the effect of total optimization.
Technical scheme
To this end, the present invention proposes a kind of amorphous alloy core body permanent-magnet brushless DC electric machine, applicable rated power is not less than The permanent-magnet brushless DC electric machine of 500W.
Its technical scheme is specific as follows:
A kind of amorphous alloy core body permanent-magnet brushless DC electric machine, is made up of motor body and controller two parts, motor body Part include motor upper cover, motor bottom end cover, motor output shaft, wire hole, cross line guard ring, axle sleeve, upper skeleton, lower skeleton, Stator coil, stator core body, rotor core body, Nd-Fe-B permanent magnetic block, upper bearing (metal), lower bearing, fixed screw, controller part Including aluminum metal-matrix printed substrate, control cable, control to drive with power VMOS tube, position with double-core single-chip microcomputer, motor Sensing and use Hall element A, Hall element B, Hall element C, it is characterized by: described amorphous alloy core body brushless, permanently is straight Stream motor is that electromechanical integrated structure, motor body and controller are all encapsulated in motor upper cover and motor bottom end cover, described Stator core body be formed by stacking by the multi-disc amorphous alloy film having line embedding groove, and be fixed on by upper skeleton and lower skeleton In the supporter of composition, each line bag of the stator coil of coiling aftershaping is mutually the most embedding to be arranged on upper skeleton and lower skeleton, Described rotor core body is formed by stacking by non-crystaline amorphous metal rotor core sheet, real by four annular plush coppers on rotor core sheet Behind existing multi-disc overlapping location, then it is fixed into rotor core body, rotor by four location pilot holes thereon through exhausted magnetic screw Being evenly distributed with eight V-arrangement openings on iron core punching edge, the Nd-Fe-B permanent magnetic block of eight pieces of tiles is embedded in rotor respectively On iron core edge between two adjacent V-arrangement openings, on described motor output shaft, tight fit installs the axle sleeve of a fluting, Rotor core body is arranged on the axle sleeve of fluting by rotor core centre bore, and described controller component and circuit are fully integrated On aluminum metal-matrix printed substrate, its aluminum metal-matrix printed substrate is respectively by the layer printed circuit board on upper strata, middle heat conduction Insulating barrier and support aluminum metal cylinder composition, its thermally conductive insulating layer is the epoxy resin of high thermal conductivity inorganic filler, it Make layer printed circuit board closely bond integral with supporting aluminum metal cylinder, engrave on the cylindrical round surface of aluminum metal supporting Have external screw thread, metal core printed circuit board by its support on aluminum metal cylinder screw in motor bottom end cover interior In wall screw thread, then passed the technology hole phase of the fixed screw holes on aluminum metal-matrix printed substrate and upper skeleton by screw Fixed is fixed, and the described Copper Foil on layer printed circuit board is etched into electric machine controller circuit, respectively Surface Mount and be welded with power VMOS Pipe, double-core single-chip microcomputer, Hall element A, Hall element B, Hall element C, supporting the cylindrical protrusion that is backed with of aluminum metal Archimedian screw shape vent rib.
Motor upper cover, motor bottom end cover are on aluminum alloy die casting, motor upper cover and motor bottom end cover and are respectively arranged with one Wire hole, controls cable one end and is welded on aluminum metal-matrix printed substrate, and the other end is through the mistake being embedded in wire hole mutually Draw after line guard ring, be integrally forming by four fixed screw fixed installations respectively between motor upper cover and motor bottom end cover.
Controlling cable is eight core cables, represents positive source (VCC), ground wire (GND), electric motor starting/stopping respectively (ENBL), motor positive and inverse (F/R), brake signal (BRK), speed governing (SPEED), VD (+5V), common port (COM), wherein, electricity Machine starts/stops the external electric motor starting/shutdown switch of (ENBL) line, and the external motor positive and inverse of motor positive and inverse (F/R) line switchs, Brake signal (BRK) line external braking signal switch pedal, described speed governing (SPEED), VD (+5V), common port (COM) are external Speed control crank.
Double-core single-chip microcomputer Surface Mount is welded at MCU pad, double-core single-chip microcomputer except from translator control necessary capture/ Outside comparing unit kernel, it is integrated with in chip for high-speed multiply division arithmetic unit (iMDU) simultaneously and is used for coordinating rotating vector Digital computing unit (iCORDIC) kernel, described position sensor Hall element A plug-in mounting is welded on aluminum metal-matrix track At the Hall element A welding hole of road plate, Hall element B plug-in mounting be welded at the Hall element B welding hole of aluminum metal-matrix printed substrate, Hall element C plug-in mounting is welded at the Hall element C welding hole of aluminum metal-matrix printed substrate, Hall element A, Hall element B, suddenly After the pin of you element C each passes aluminum metal-matrix printed substrate, its magnetic induction body is embedded in stator core body three mutually The gap of adjacent line embedding groove, wherein the magnetic induction face of Hall element B and Hall element A, the magnetic induction plane phase of Hall element C Instead, rotor core body rotate time, the Nd-Fe-B permanent magnetic block of tile respectively close to by the magnetic induction plane of Hall element A, suddenly That the magnetic induction reverse side of element B, the magnetic induction plane of Hall element C.
There is step in the upper end cover of support upper bearing (metal) on described motor upper cover, motor bottom end cover has shaft outlet hole and support Step in the bottom end cover of lower bearing, has a central circular hole in the middle position of aluminum metal-matrix printed substrate, and motor exports One end of axle connects bearing through the centre bore rear enclosure of aluminum metal-matrix printed substrate, and upper bearing (metal) is inlaid into step in upper end cover again In, the other end of motor output shaft socket lower bearing, lower bearing is inlaid in bottom end cover in step, motor output shaft then under Shaft outlet hole on end cap stretches out.
Described stator coil is made up of 12 line bags altogether, each line bag respectively with oxygen-free copper (OFC) (OFC, i.e. " Oxygen Free Copper " English abbreviation) enamel-covered wire coiling forms.
Technique effect
The amorphous alloy core body permanent-magnet brushless DC electric machine that the present invention proposes has the advantages that
1, amorphous alloy core body permanent-magnet brushless DC electric machine of the present invention, in frame for movement, it change permanent magnetism without Brushless motor is installed separately with controller, reconnect use conventional mounting pattern, but by motor body and controller, hold Row mechanism takes integral structure, instead of various external control wire harness, eliminates conventional permanent magnet brushless direct current generator external Three U, V, W phase lines provided and five position sensor device control lines, enhance its reliability, it is achieved that system saves most, whole Body is optimum.
2, amorphous alloy core body permanent-magnet brushless DC electric machine of the present invention, its non-crystaline amorphous metal replaces stalloy application In electric machine stator iron and rotor core, it is possible to improve efficiency and the power density of motor to a great extent, reduce iron loss; By using the line bag of oxygen-free copper (OFC) enamel-covered wire coiling stator coil to reduce copper loss, the energy conservation and consumption reduction effects making motor is bright Aobvious.
3, in heat radiation topological structure, by have employed the controller unit that aluminum metal-matrix printed substrate solves well Part is at the connectivity problem of printed substrate;Revolve, with motor metal shell, the combination side being integrated by aluminum metal-matrix printed substrate Formula, improves heat conductivity, solves the heat dissipation problem of the power VMOS tube of controller.
4, by employing low cost, efficient double-core single-chip microcomputer replaces dsp chip, solves motor High-speed Control and core Contradiction between sheet price, greatly reduces manufacturing cost.
5, the position sensor Hall element of traditional permanent-magnet brushless DC electric machine, is all to be sealed by manual setting, resin Being contained in stator core space, its pin is externally drawn by line again, and usually location is inaccurate, and the present invention is directly by Hall element Pin is welded on the printed substrate of electric machine controller, and position sensing positional accuracy is high, and concordance is good, is a kind of brand-new Position sensor localization method.
6, in the case of same output, amorphous alloy core body permanent-magnet brushless DC electric machine of the present invention can Obtaining excellent energy-saving and cost-reducing characteristic, its volume only has the 60% of conventional motors, and weight only has 75%, intrinsic in eddy current and material Magnetic hystersis loss can decline about 20%.
Obviously, amorphous alloy core body permanent-magnet brushless DC electric machine of the present invention, is the most no longer a kind of monotechnics Or the alternative and upgrading of the simple effective material of motor, but a kind of comprehensive conservation measures and brand-new control topologies collection Close.
Accompanying drawing explanation
Fig. 1 amorphous alloy core body permanent-magnet brushless DC electric machine forward explosive view one;
Fig. 2 amorphous alloy core body permanent-magnet brushless DC electric machine forward outline drawing;
Fig. 3 amorphous alloy core reverse outline drawing of body permanent-magnet brushless DC electric machine;
Fig. 4 removes the forward interior views after motor upper cover and motor bottom end cover;
Fig. 5 removes the reverse interior views after motor upper cover and motor bottom end cover;
Fig. 6 removes the interior views after motor upper cover, motor bottom end cover and rotor core body;
Fig. 7 removes the explosive view two after motor upper cover and motor bottom end cover;
Fig. 8 removes the explosive view three after motor upper cover, motor bottom end cover and double-core single-chip microcomputer;
Fig. 9 amorphous alloy core body permanent-magnet brushless DC electric machine backlash figure four;
Figure 10 amorphous alloy core body permanent-magnet brushless DC electric machine forward explosive view five.
Label declaration:
1 motor upper cover 2 motor bottom end cover
3 motor output shaft 4 fixed screws
5 control cable 6 aluminum metal-matrix printed substrate
7 power VMOS tube 8 double-core single-chip microcomputers
9 Hall element A 10 Hall element B
11 Hall element C 12 stator coils
13 upper skeleton 14 lower skeletons
15 stator core body 16 rotor core bodies
17 Nd-Fe-B permanent magnetic block 18 upper bearing (metal)s
19 lower bearing 20 wire holes
21 annular plush coppers 22 position pilot hole
23 inner thread 24 external screw threads
25 MCU pad 26 Hall element A welding holes
27 Hall element B welding hole 28 Hall element C welding holes
29 rotor core centre bore 30 Archimedian screw shape vent ribs
Step in step 32 bottom end cover in 31 upper end covers
33 cross line guard ring 34 technology hole
35 V-arrangement opening 36 shaft outlet holes
37 line embedding groove 38 central circular holes
39 axle sleeve 40 fixed screw holes
Detailed description of the invention
The present invention is as shown in Figures 1 to 10.
Specific embodiments of the present invention are described below in conjunction with the accompanying drawings.
A kind of amorphous alloy core body permanent-magnet brushless DC electric machine, is made up of motor body and controller two parts, motor Body part includes on motor upper cover 1, motor bottom end cover 2, motor output shaft 3, motor upper cover 1 and motor bottom end cover 2 Wire hole 20, line guard ring 33, axle sleeve 39, upper skeleton 13, lower skeleton 14, stator coil 12, stator core body 15, rotor core excessively Body 16, Nd-Fe-B permanent magnetic block 17, upper bearing (metal) 18, lower bearing 19, fixed screw 4, controller part includes aluminum metal-matrix track Road plate 6, control cable 5, double-core single-chip microcomputer 8, power VMOS tube 7, position sensing Hall element A 9, Hall element B 10, Hall element C 11, it is characterized by: described amorphous alloy core body permanent-magnet brushless DC electric machine is electromechanical integrated structure, Motor body and controller are all encapsulated in motor upper cover 1 and motor bottom end cover 2, and described stator core body 15 is embedding by having The multi-disc amorphous alloy film of wire casing 37 is formed by stacking, and is fixed on the supporter being made up of upper skeleton 13 and lower skeleton 14 In, each line bag of the stator coil 12 of coiling aftershaping is mutually the most embedding to be arranged on upper skeleton 13 and lower skeleton 14, described Rotor core body 16 is formed by stacking by non-crystaline amorphous metal rotor core sheet, without winding on rotor, by four on rotor core sheet After annular plush copper 21 realizes multi-disc overlapping location, then position the pilot holes 22 exhausted magnetic spiral shell through non-magnetizer by four thereon Silk is fixed into rotor core body 16, and rotor core body 16 punching edge is evenly distributed with eight V-arrangement openings 35, eight pieces of tiles Nd-Fe-B permanent magnetic block 17 be embedded on rotor core body 16 edge between two adjacent V-arrangement openings 35 respectively, due to neodymium ferrum Boron permanent magnets 17 is positioned on the outer surface of rotor core body 16, it is provided that flow direction be radially, such Nd-Fe-B permanent magnetic block 17 Region be directly facing even air gap, particularly the favorable orientation of Nd-Fe-B permanent magnetic block 17, therefore can obtain and there is preferable square-wave form Air-gap field.
On described motor output shaft 3, tight fit installs the axle sleeve 39 of the fluting of a non-magnetizer, rotor core body 16 Being arranged on the axle sleeve 39 of fluting by rotor core centre bore 29, described controller component and circuit are fully integrated into aluminium gold Belonging on base printed substrate 6, its aluminum metal-matrix printed substrate 6 is respectively by the layer printed circuit board on upper strata, middle heat conductive insulating Layer and support aluminum metal cylinder composition, its thermally conductive insulating layer is the epoxy resin of high thermal conductivity inorganic filler, and it makes print Brush circuit layer closely bonds integral with supporting aluminum metal cylinder, outside having engraved on the support cylindrical round surface of aluminum metal Screw thread 24, metal core printed circuit board 6 is screwed in motor bottom end cover 2 by its external screw thread 24 supported on aluminum metal cylinder In inner thread 23, then with screw through the fixed screw holes 40 on aluminum metal-matrix printed substrate 6 and the work on upper skeleton 13 Hole 34, skill location is fixedly connected, and the described Copper Foil on aluminum metal-matrix printed substrate 6 is etched into electric machine controller circuit, respectively Surface Mount and be welded with power VMOS tube 7, double-core single-chip microcomputer 8, Hall element A 9, Hall element B 10, Hall element C 11, Support the cylindrical Archimedian screw shape vent rib 30 being backed with protrusion of aluminum metal.
Described motor upper cover 1, motor bottom end cover 2 are aluminum alloy die casting, and the proportion of aluminum is little, can alleviate motor Weight, and aluminum belongs to non-magnetizer, can reduce the leakage field of main field;It is respectively arranged with a wire hole on motor upper cover 1 and motor bottom end cover 2 20, the one end controlling cable 5 is welded on aluminum metal-matrix printed substrate 6, and the other end is through being embedded in wire hole 20 mutually Draw after crossing line guard ring 33, fixedly mounted into by four fixed screws 4 respectively between motor upper cover 1 with motor bottom end cover 2 Integrally.
Described control cable 5 is eight core cables, represents positive source (VCC) respectively, ground wire (GND), motor open Dynamic/stopping (ENBL), motor positive and inverse (F/R), brake signal (BRK), speed governing (SPEED), VD (+5V), common port (COM), Wherein, the external electric motor starting/shutdown switch of electric motor starting/stopping (ENBL) line, the external motor of motor positive and inverse (F/R) line is positive and negative Turn on pass, brake signal (BRK) line external braking signal switch pedal, described speed governing (SPEED), VD (+5V), common port (COM) external speed control crank.
Visible, external interface signal line provided by the present invention, eliminate conventional permanent magnet brushless direct current generator completely external Three U, V, W phase lines provided and five position sensor device control lines, it is only necessary to two power lines and five external control letters Number, enhance its reliability, it is achieved that system saves most, total optimization.
Described double-core single-chip microcomputer 8 Surface Mount is welded at the MCU pad 25 of aluminum metal-matrix printed substrate 6, double-core monolithic Machine 8, in addition to controlling necessary capture/comparing unit kernel from translator, is integrated with for high-speed multiply division in chip simultaneously Arithmetic element (iMDU) and for coordinating digital computing unit (iCORDIC) kernel of rotating vector, described position sensor Hall element A 9 plug-in mounting is welded at the Hall element A welding hole 26 of aluminum metal-matrix printed substrate 6, Hall element B 10 plug-in mounting Be welded at Hall element B welding hole 27, Hall element C 11 plug-in mounting is welded at Hall element C welding hole 28, Hall element A 9, After Hall element B 10, the pin of Hall element C 11 each pass aluminum metal-matrix printed substrate 6, its magnetic induction body just phase It is embedded in the gap of the adjacent line embedding groove 37 of stator core body 15 3, wherein the magnetic induction face of Hall element B 10 and Hall element A 9, Hall element C 11 magnetic induction plane contrary, when rotor core body rotates, the Nd-Fe-B permanent magnetic block 17 of tile is respectively Near by the magnetic induction plane of Hall element A 9, the magnetic induction reverse side of Hall element B 10, the magnetic induction of Hall element C 11 Plane.By contrast, the position sensor Hall element of traditional permanent-magnet brushless DC electric machine, is all fixed by resin-encapsulated In son space unshakable in one's determination, its pin is externally drawn by line again, and shortcoming is to position less accurate, and slightly will to affect it fixed for deviation Position output signal, causes position error, and Hall element pin is directly welded on the printed substrate of electric machine controller by the present invention On, position sensing positional accuracy is high, is a kind of brand-new position sensor localization method.
There is step 31 in the upper end cover of support upper bearing (metal) 18 on described motor upper cover 1, motor bottom end cover 2 has shaft outlet hole 36 and support lower bearing 19 bottom end cover in step 32, have central authorities in the middle position of aluminum metal-matrix printed substrate 6 Circular hole 38, one end of motor output shaft 3 connects bearing 18 through central circular hole 38 rear enclosure of aluminum metal-matrix printed substrate 6, on Bearing 18 is inlaid in upper end cover in step 31 again, and the other end socket lower bearing 19 of motor output shaft 3, lower bearing 19 is inlaid into In bottom end cover in step 32, the motor output shaft 3 then shaft outlet hole 36 from bottom end cover 2 stretches out.
Described stator coil 12 is made up of 12 line bags altogether, and oxygen-free copper (OFC) enamel-covered wire coiling used respectively by each line bag, Compared with traditional enamel covered wire, electrical conductivity is cathode copper the 109.0% of oxygen-free copper-wire (OFC), resistivity ratio routine enamel-covered wire Less, welding performance, corrosion resisting property and cryogenic property are all more preferable than conventional enamel-covered wire, and particularly its hardness is little, flexible, rolls off the production line Convenient, copper loss can be substantially reduced, more meaningful, oxygen-free copper-wire (OFC) creates distinctive gold owing to making the surface of copper cash Belong to structure, make the surface of same copper conductor be suitable for transmitting the pwm signal of more than 5kHz, and its center is particularly suitable for transmitting 5kHz Following pwm signal, so that high and low frequency pwm control signal is taken their own roads, does not disturbs.Although having selected oxygen-free copper-wire, On the high side, but owing to electromagnetic system magnetic flux density B is high, with the same power permanent magnetic brushless dc motor using common enamel-covered wire Comparing, the line bag number of turn can reduce nearly 10%, can save the most again copper nearly 10%.
Here it is noted that the method for traditional electric machine controller power device heat radiation has two kinds, one is directly to use Copper Foil printed wiring board dispels the heat, the most common FR4 printed substrate, but for electric machine controller, big electric current FR4 printed substrate is made to be difficult to bear high heat with powerful drive circuit, because the thermal conductance of FR4 printed substrate Rate is only 0.36W/ (m.K), and thermal coefficient of expansion is 13~17ppm/K;Two is directly power VMOS tube to be directly installed on height On heat conducting and heat radiating fin, externally dispelled the heat by the fin on fin or rib, it is clear that increase newly again in a motor body structure The scheme being carried out the heat radiation of auxiliary power device by multiple fin is difficult to implement, this most existing brshless DC motor Body and controller separate independent main cause.
It is in place of the novel creation of the present invention: devising the heat radiation topological structure of a kind of uniqueness, one is real easily Motor body and the two-part effective connection of controller are showed;Two substantially increase the internal high hot driving of controller to outside Heat conductivity.Power VMOS tube 7 is mounted on aluminum metal-matrix printed substrate 6, is the excellent of heat owing to supporting aluminum metal cylinder Good conduction material, and support the cylindrical back side of aluminum metal and have the Archimedian screw shape vent rib 30 of protrusion, therefore, electricity During the work of road, the heat that power VMOS tube 7 produces will not present concentration of local, and its hot-fluid will radially flow, and aluminum metal Base printed substrate 6 screws in the inner thread 23 in motor bottom end cover 2 by its external screw thread 24 supported on aluminum metal cylinder, And connect into an entirety, so that the high heat that power VMOS tube 7 produces can be emitted into outside quickly through motor bottom end cover 2, On the other hand, owing to upper end cover 1 and bottom end cover 2 are to be connected to form an entirety by fixed screw, therefore there is high heat conduction system The upper end cover 1 of aluminum alloy die casting of the number heat radiation task that motor is external with bottom end cover 2 shared, thus expand heat radiation Area.
The short circuit caused, described aluminum metal-matrix is tilted by producing heat during for preventing thermal coefficient of expansion difference between different materials The thermally conductive insulating layer of the centre of printed substrate 6, uses the epoxide resin material of high thermal conductivity inorganic filler, passes through The press mold technology of thin combination makes layer printed circuit board closely bond with supporting aluminum metal cylinder.
The most important innovation of the present invention also resides in, and stator core body 15 and rotor core body 16 all use amorphous alloy film to fold The non-crystaline amorphous metal body closed, its magnetic of non-crystaline amorphous metal is strong, soft magnet performance is better than stalloy, moderate, greatly reduces whirlpool Magnetic hystersis loss intrinsic in stream and material.The result of computer simulation emulation proves, non-crystaline amorphous metal is in the case of frequency 1KHz, non- The core loss of peritectic alloy is 7.77w/kg, and its eddy-current loss can decline 17%, reduce 58.8% than silicon steel stator core.
Relatively thin for amorphous alloy film, very sensitive to mechanical stress, hold owing to local deformation amount is excessive when stretching Easy fracture, the feature that elongation percentage is the lowest, this invention takes following design, shear for the ease of laser punching processing and obtain Excellent Frequency Power Loss characteristic, is made annealing treatment amorphous alloy iron core sheet, but fragility after amorphous alloy iron core sheet annealing Relatively big, therefore to structurally avoid with amorphous alloy core as main load-bearing structural member, especially stator core body 15 is pacified Dress is fixed in the supporter being made up of upper skeleton 13 and lower skeleton 14, reduces tension force or bending stress pair to the full extent The impact of stator core body 15 magnetic property, described upper skeleton 13 and lower skeleton 14 all use fire-retardant high heat-resistant engineering plastic.Non- When peritectic alloy lamination makees rotor core, it is considered to the impact of centrifugal force, therefore first pass through four annular plush coppers on rotor core sheet 21 realize multi-disc overlapping location, and the existence of annular plush copper 21 increases the frictional resistance between rotor core sheet simultaneously, then lead to Cross four circular location pilot holes 22 thereon and be fixed into rotor core body 16, to strengthen rotor core body through exhausted magnetic screw Bulk strength.
In sum, the substantial improvements of the present invention is:
1, in frame for movement, change motor body and separately manufacture and design with controller, be respectively mounted, then by electric wire cable Connect the traditional mode used, but motor body and controller are taked integral structure, applicable rated power are not less than The permanent-magnet brushless DC electric machine of 500W, owing to instead of various control wire harness, eliminates conventional permanent magnet brushless direct current generator institute Three U, V, W phase lines needed and five hall position sensor device control lines, so that the control cable of outside extraction is Eight core cables, enhance reliability, improve ease for use, it is achieved that system saves most and total optimization.
2, on effective material of motor manufacturing, use non-crystaline amorphous metal to replace silicon steel, apply simultaneously to electric machine stator iron And rotor core, non-crystaline amorphous metal is compared with traditional stalloy, and the coercivity of non-crystaline amorphous metal is the 1/7 of cold-rolled orientation silicon steel sheet Left and right, the area of the hysteresis curve institute envelope of non-crystaline amorphous metal is much smaller than cold-rolled orientation silicon steel sheet, and therefore the magnetic hysteresis of non-crystaline amorphous metal is damaged Loss-rate cold-reduced silicon sheet is much smaller, under high rotating speed and high power, the loss of non-crystaline amorphous metal can be reduced to stalloy three/ One.
3, the deficiency thin in order to overcome non-crystaline amorphous metal crispy slice, the present invention has been designed with based on fire-retardant high-temperature resistant engineering Plastics constitute upper skeleton and lower skeleton as stator core supporter to fixedly mount stator core body.
4, by using oxygen-free copper enamel-covered wire coiling stator coil bag to reduce copper loss, kelvin effect is greatly reduced, The energy conservation and consumption reduction effects making motor is obvious, improves efficiency and the power density of motor simultaneously.
5, in heat radiation topological structure, by using aluminum metal-matrix printed substrate to solve controller component at track The connectivity problem of road plate, revolves, with motor metal shell, the design being integrated by aluminum metal-matrix printed substrate, improves its heat Conducting power, solve the heat dissipation problem of power VMOS tube, and achieve effectively being connected of controller and motor body.
6, the dsp chip that the replacement of employing double-core single-chip microcomputer is expensive, double-core single-chip microcomputer built-in Hall position inspection software module, Protection module and rotating vector computing module, solve motor and control the contradiction between chip price the most in real time, greatly Reduce greatly manufacturing cost.
7, directly the pin of position sensor Hall element is welded on metal core printed circuit board, the magnetic of Hall element Sensitive surface is accurately encapsulated in stator core space, it is achieved that the location side of the brand-new sensing rotor current location that concordance is good Case.
8, the present invention is proved by three-dimensional digital Prototype Design and computer simulation emulation, with the permanent magnetism of Same Efficieney without Brushless motor is compared, and can obtain following beyond thought energy-saving effect: its volume only has conventional permanent magnet brushless direct current generator to add The 60% of upper controller volume, weight only have its 75%, magnetic hystersis loss intrinsic in eddy current and material can decline about 20%, copper loss Decline 18%.
In a word, amorphous alloy core body permanent-magnet brushless DC electric machine of the present invention, be the most no longer by monotechnics or The permanent-magnet brushless DC electric machine of traditional method design, but one to combine electrical material, machine-building, control topology multidisciplinary The system integration of technology.Undoubtedly, this is a kind of good reliability, use is simple, be widely used, highly promising novel permanent magnetic is brushless Direct current generator, is suitable for military project and high-end electronic product and the application in market, is existing permanent-magnet brushless DC electric machine and motor control The renewal product of device.

Claims (6)

1. an amorphous alloy core body permanent-magnet brushless DC electric machine, is made up of motor body and controller two parts, and motor is originally Body portion include motor upper cover (1), motor bottom end cover (2), motor output shaft (3), wire hole (20), cross line guard ring (33), Axle sleeve (39), upper skeleton (13), lower skeleton (14), stator coil (12), stator core body (15), rotor core body (16), neodymium Ferrum boron permanent magnets (17), upper bearing (metal) (18), lower bearing (19), fixed screw (4), controller part includes aluminum metal-matrix track Road plate (6), control cable (5), double-core single-chip microcomputer (8), power VMOS tube (7), Hall element A(9), Hall element B(10), Hall element C(11), it is characterised in that:
Described amorphous alloy core body permanent-magnet brushless DC electric machine is that electromechanical integrated structure, motor body and controller all seal Being contained in motor upper cover (1) interior with motor bottom end cover (2), described stator core body (15) is by the multi-disc having line embedding groove (37) Amorphous alloy film is formed by stacking, and is fixed in the supporter being made up of upper skeleton (13) and lower skeleton (14), after coiling Each line bag of the stator coil (12) of molding is mutually the most embedding to be arranged on upper skeleton (13) and lower skeleton (14), described rotor Iron core (16) is formed by stacking by non-crystaline amorphous metal rotor core sheet, is realized by four annular plush coppers (21) on rotor core sheet Behind multi-disc overlapping location, then it is fixed into rotor core body by four location pilot hole (22) thereon through exhausted magnetic screw (16), rotor core body (16) punching edge is evenly distributed with eight V-arrangement openings (35), the Nd-Fe-B permanent magnetic of eight pieces of tiles Block (17) is embedded on rotor core body (16) edge between two adjacent V-arrangement openings (35) respectively, described motor output The upper tight fit of axle (3) installs the axle sleeve (39) of a fluting, and rotor core body (16) is installed by rotor core centre bore (29) On the axle sleeve (39) of fluting, described controller component and circuit are fully integrated on aluminum metal-matrix printed substrate (6), its Aluminum metal-matrix printed substrate (6) is respectively by the layer printed circuit board on upper strata, middle thermally conductive insulating layer and support aluminum metal cylinder Body forms, and its thermally conductive insulating layer is the epoxy resin of high thermal conductivity inorganic filler, and it makes layer printed circuit board and supports aluminium gold Belong to cylinder and closely bond integral, engrave external screw thread (24), aluminum metal-matrix supporting on the cylindrical round surface of aluminum metal Printed substrate (6) supports the external screw thread (24) on aluminum metal cylinder by it and screws in the inwall spiral shell in motor bottom end cover (2) In stricture of vagina (23), then pass on the fixed screw holes (40) on aluminum metal-matrix printed substrate (6) and upper skeleton (13) with screw Technology hole (34) is fixedly connected, and the described Copper Foil on aluminum metal-matrix printed substrate (6) is etched into electric machine controller electricity Road, respectively Surface Mount and be welded with power VMOS tube (7), double-core single-chip microcomputer (8), Hall element A(9), Hall element B(10), suddenly You are element C(11), supporting cylindrical Archimedian screw shape vent rib (30) being backed with protrusion of aluminum metal.
Amorphous alloy core body permanent-magnet brushless DC electric machine the most according to claim 1, it is characterised in that: motor upper cover (1), motor bottom end cover (2) is on aluminum alloy die casting, motor upper cover (1) and motor bottom end cover (2) and is respectively arranged with a wire hole (20), the one end controlling cable (5) is welded on aluminum metal-matrix printed substrate (6), and the other end is through being embedded in wire hole mutually (20) the line guard ring (33) of crossing in is drawn afterwards, passes through fixed screw respectively between motor upper cover (1) and motor bottom end cover (2) (4) fixed installation.
Amorphous alloy core body permanent-magnet brushless DC electric machine the most according to claim 1 and 2, it is characterised in that: described Controlling cable (5) is eight core cables, represents positive source (VCC), ground wire (GND), electric motor starting/stopping respectively (ENBL), motor positive and inverse (F/R), brake signal (BRK), speed governing (SPEED), VD (+5V), common port (COM), wherein, electricity Machine starts/stops the external electric motor starting/shutdown switch of (ENBL) line, and the external motor positive and inverse of motor positive and inverse (F/R) line switchs, Brake signal (BRK) line external braking signal switch pedal, described speed governing (SPEED), VD (+5V), common port (COM) are external Speed control crank.
Amorphous alloy core body permanent-magnet brushless DC electric machine the most according to claim 1, it is characterised in that: described double-core Single-chip microcomputer (8) Surface Mount is welded at MCU pad (25) place of aluminum metal-matrix printed substrate (6), and double-core single-chip microcomputer (8) is except carrying Motor controls, outside necessary capture/comparing unit kernel, to be integrated with for high-speed multiply division arithmetic unit in chip simultaneously (iMDU) with for coordinating digital computing unit (iCORDIC) kernel of rotating vector, described position sensor Hall element A (9) plug-in mounting is welded on Hall element A welding hole (26) place of aluminum metal-matrix printed substrate (6), Hall element B(10) plug-in mounting welding At Hall element B welding hole (27) place, Hall element C(11) plug-in mounting is welded on Hall element C welding hole (28) place, Hall element A (9), Hall element B(10), Hall element C(11) pin each through after aluminum metal-matrix printed substrate (6), its magnetic induction Body is embedded in the gap of (15) three adjacent line embedding grooves (37) of stator core body, wherein Hall element B(10 mutually) magnetic strength Answer face and Hall element A(9), Hall element C(11) magnetic induction plane contrary, rotor core body (16) rotate time, tile Nd-Fe-B permanent magnetic block (17) respectively close to by Hall element A(9) magnetic induction plane, Hall element B(10) magnetic induction Reverse side, Hall element C(11) magnetic induction plane.
Amorphous alloy core body permanent-magnet brushless DC electric machine the most according to claim 1, it is characterised in that: on described motor There is step (31) in the upper end cover of support upper bearing (metal) (18) on end cap (1), motor bottom end cover (2) has shaft outlet hole (36) and supports Step (32) in the bottom end cover of lower bearing (19), has central authorities' circle in the middle position of aluminum metal-matrix printed substrate (6) Hole (38), one end of motor output shaft (3) connects bearing through central circular hole (38) rear enclosure of aluminum metal-matrix printed substrate (6) (18), in upper bearing (metal) (18) is inlaid into upper end cover again, step (31) is interior, the other end socket lower bearing of motor output shaft (3) (19), lower bearing (19) is inlaid in bottom end cover in step (32), motor output shaft (3) the then shaft from bottom end cover (2) Hole (36) is stretched out.
Amorphous alloy core body permanent-magnet brushless DC electric machine the most according to claim 1, it is characterised in that: described stator Coil (12) is made up of 12 line bags altogether, and each line bag forms with oxygen-free copper enamel-covered wire coiling respectively.
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CN107317452A (en) * 2017-08-21 2017-11-03 彭希南 Integrated permanent magnetism brushless direct current wheel hub motor
CN107612226A (en) * 2017-10-31 2018-01-19 珠海格力电器股份有限公司 Surface mounting structure, surface mount method, motor and surface mount chip
CN108599470A (en) * 2018-06-04 2018-09-28 彭希南 A kind of open permanent-magnet brushless DC electric machine movement
CN108667226A (en) * 2018-06-04 2018-10-16 彭希南 A kind of flat three-phase permanent brshless DC motor movement
CN108730218A (en) * 2018-06-04 2018-11-02 彭希南 A kind of Full-automatic Variable Frequency Speed Regulation ventilation fan
CN109936234A (en) * 2017-12-15 2019-06-25 中华汽车工业股份有限公司 The motor for automobile of built-in charging control function
CN110892616A (en) * 2017-07-13 2020-03-17 日立汽车系统株式会社 Electric drive device and electric power steering device
CN110971086A (en) * 2018-09-28 2020-04-07 本田技研工业株式会社 Motor structure
CN112928871A (en) * 2019-12-05 2021-06-08 上海发腾航空科技有限公司 Mounting structure of direct current motor circuit board
TWI820153B (en) * 2018-07-12 2023-11-01 瑞士商力威磁浮技術有限公司 An electromagnetic rotary drive and a rotational device

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JP2009065746A (en) * 2007-09-05 2009-03-26 Teikoku Electric Mfg Co Ltd Canned motor drive system
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Publication number Priority date Publication date Assignee Title
CN106411088A (en) * 2016-12-20 2017-02-15 深圳市万至达电机制造有限公司 Steering motor of mobile robot platform
CN106411088B (en) * 2016-12-20 2019-07-02 深圳市万至达电机制造有限公司 A kind of steering motor of mobile robot's platform
CN110892616B (en) * 2017-07-13 2021-07-02 日立安斯泰莫株式会社 Electric drive device and electric power steering device
CN110892616A (en) * 2017-07-13 2020-03-17 日立汽车系统株式会社 Electric drive device and electric power steering device
CN107317452A (en) * 2017-08-21 2017-11-03 彭希南 Integrated permanent magnetism brushless direct current wheel hub motor
CN107612226A (en) * 2017-10-31 2018-01-19 珠海格力电器股份有限公司 Surface mounting structure, surface mount method, motor and surface mount chip
CN107612226B (en) * 2017-10-31 2024-05-03 珠海格力电器股份有限公司 Surface mounting structure, surface mounting method, motor and surface mounting chip
CN109936234A (en) * 2017-12-15 2019-06-25 中华汽车工业股份有限公司 The motor for automobile of built-in charging control function
CN108599470B (en) * 2018-06-04 2020-02-14 彭希南 Open permanent magnet brushless direct current motor core
CN108667226B (en) * 2018-06-04 2020-02-14 彭希南 Flat three-phase permanent magnet brushless direct current motor core
CN108730218A (en) * 2018-06-04 2018-11-02 彭希南 A kind of Full-automatic Variable Frequency Speed Regulation ventilation fan
CN108667226A (en) * 2018-06-04 2018-10-16 彭希南 A kind of flat three-phase permanent brshless DC motor movement
CN108599470A (en) * 2018-06-04 2018-09-28 彭希南 A kind of open permanent-magnet brushless DC electric machine movement
TWI820153B (en) * 2018-07-12 2023-11-01 瑞士商力威磁浮技術有限公司 An electromagnetic rotary drive and a rotational device
CN110971086A (en) * 2018-09-28 2020-04-07 本田技研工业株式会社 Motor structure
CN112928871A (en) * 2019-12-05 2021-06-08 上海发腾航空科技有限公司 Mounting structure of direct current motor circuit board

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