CN106208545B - Amorphous alloy core body permanent-magnet brushless DC electric machine - Google Patents
Amorphous alloy core body permanent-magnet brushless DC electric machine Download PDFInfo
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- CN106208545B CN106208545B CN201610818648.9A CN201610818648A CN106208545B CN 106208545 B CN106208545 B CN 106208545B CN 201610818648 A CN201610818648 A CN 201610818648A CN 106208545 B CN106208545 B CN 106208545B
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- 229910000808 amorphous metal alloy Inorganic materials 0.000 title claims abstract description 35
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 64
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 43
- 239000011159 matrix material Substances 0.000 claims abstract description 41
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 26
- 229910001172 neodymium magnet Inorganic materials 0.000 claims abstract description 14
- 238000009434 installation Methods 0.000 claims abstract description 4
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 17
- 239000010949 copper Substances 0.000 claims description 16
- 229910052802 copper Inorganic materials 0.000 claims description 16
- 229910052751 metal Inorganic materials 0.000 claims description 16
- 239000002184 metal Substances 0.000 claims description 16
- 230000006698 induction Effects 0.000 claims description 15
- 239000005300 metallic glass Substances 0.000 claims description 14
- 238000003466 welding Methods 0.000 claims description 14
- 238000005516 engineering process Methods 0.000 claims description 10
- 229910052742 iron Inorganic materials 0.000 claims description 6
- 239000000203 mixture Substances 0.000 claims description 5
- 229910000838 Al alloy Inorganic materials 0.000 claims description 4
- 239000011889 copper foil Substances 0.000 claims description 4
- 238000004512 die casting Methods 0.000 claims description 4
- 239000003822 epoxy resin Substances 0.000 claims description 4
- 229920000647 polyepoxide Polymers 0.000 claims description 4
- 238000004080 punching Methods 0.000 claims description 4
- 239000011256 inorganic filler Substances 0.000 claims description 3
- 229910003475 inorganic filler Inorganic materials 0.000 claims description 3
- 241001124569 Lycaenidae Species 0.000 claims description 2
- QJVKUMXDEUEQLH-UHFFFAOYSA-N [B].[Fe].[Nd] Chemical compound [B].[Fe].[Nd] QJVKUMXDEUEQLH-UHFFFAOYSA-N 0.000 claims description 2
- 235000014987 copper Nutrition 0.000 claims description 2
- 238000001816 cooling Methods 0.000 claims 1
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- 239000011162 core material Substances 0.000 description 96
- 229910000976 Electrical steel Inorganic materials 0.000 description 13
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- 238000013461 design Methods 0.000 description 8
- 238000004519 manufacturing process Methods 0.000 description 8
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- 230000007423 decrease Effects 0.000 description 4
- 239000002360 explosive Substances 0.000 description 4
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- 238000005457 optimization Methods 0.000 description 4
- 238000004134 energy conservation Methods 0.000 description 3
- 208000021760 high fever Diseases 0.000 description 3
- 230000009467 reduction Effects 0.000 description 3
- 238000006467 substitution reaction Methods 0.000 description 3
- 239000002887 superconductor Substances 0.000 description 3
- 229910052720 vanadium Inorganic materials 0.000 description 3
- 238000004804 winding Methods 0.000 description 3
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 239000004411 aluminium Substances 0.000 description 2
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- 238000003786 synthesis reaction Methods 0.000 description 2
- 206010037660 Pyrexia Diseases 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
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- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
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- 229910052710 silicon Inorganic materials 0.000 description 1
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Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K29/00—Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices
- H02K29/06—Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices with position sensing devices
- H02K29/08—Motors 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
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/02—Windings characterised by the conductor material
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K5/00—Casings; Enclosures; Supports
- H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
Abstract
A kind of amorphous alloy core body permanent-magnet brushless DC electric machine, it is made 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 wiring board, control cable, double-core microcontroller, power VMOS tube, Hall element, it is characterized by：The stator core body and it is formed by stacking with rotor core body by Fe-based amorphous alloy piece, stator core body supports fixation jointly by upper skeleton and lower skeleton, stator coil oxygen-free copper-wire coiling, the controller component and circuit is fully integrated into aluminum metal-matrix printed wiring board, external screw thread has been engraved on the support aluminum metal cylinder of aluminum metal-matrix printed wiring board, screwed in during installation in the inner thread in motor bottom end cover, form motor body and controller electromechanical integrated structure.
Description
Technical field
Amorphous alloy core body permanent-magnet brushless DC electric machine of the present invention, is a kind of high power density and efficient nothing
Brushless motor, is mainly used for space flight and aviation, New-energy electric vehicle, all kinds of high end home electric appliances and Industry Control drive area.
Background technology
Since 1978, it is brushless straight that former Mannasman company of West Germany is proposed first square wave on Hanover's trade fair
Since galvanic electricity machine and its driver, permanent-magnet brushless DC electric machine manufacture and control technology in terms of have been achieved for it is considerable into
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 speed regulating motor control field.But permanent-magnet brushless DC electric machine manufacture at present is effective
Material such as electrical sheet, conductive material substantially still follow traditional silicon steel sheet and enameled wire, so, existing DC permanent-magnetic brushless
The energy-saving space that still has greatly improved of motor, the Energy Efficiency Ratio and power density of motor need to be further improved.It is another
Aspect, permanent-magnet brushless DC electric machine, all using motor body and controller independence divided mode, are led in installation and control model
Existing permanent-magnet brushless DC electric machine is caused to be used alone using upper all inconveniences, mainly permanent-magnet brushless DC electric machine,
It must coordinate with controller to work normally, and there are between permanent-magnet brushless DC electric machine and controller many numerous and diverse
Line is controlled, is got up using identification very troublesome, and connecting line is also had a greatly reduced quality using the reliability of connector.With new energy
Source electric car it is in the ascendant, the development of Power Electronic Technique and the raising of global energy-saving and emission-reduction consciousness, develop efficient section
Energy type permanent-magnet brushless DC electric machine has been trend of the times.
Obviously, to lift the efficiency quality of permanent-magnet brushless DC electric machine should take multi-pronged measure：First, performance
Improve the application for be unableing to do without high-performance conductive material and permeability magnetic material；Secondly permanent-magnet brushless DC electric machine needs on the topology
There is great strategic structural, could realize the integral structure of motor body and controller；Importantly, DC permanent-magnetic brushless
Motor and control system belong to the electromechanical product being combined, therefore, most important innovation is still electricity as electromechanical integrated product
The system integration and technological synthesis of machine and control unit.As it can be seen that 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 current permanent-magnet brushless DC electric machine research hot spot, and permanent magnetism without
The important innovation and development direction of brushless motor.
The content of the invention
Technical problem
In order to develop energy-efficient permanent-magnet brushless DC electric machine, said from the material used, first should be from traditional
Come out of in the traditional mode of selection sorting.At present, traditional permanent-magnet brushless DC electric machine stator winding still uses common enamel-cover
Line, and the PWM high-frequency modulation signals of Controller for PM DC Brushless Motor output are at least 10 times of motor operation highest frequency
Left and right, kelvin effect of the common enameled wire under high frequency high current is obvious, and in the case of high-power, copper loss and fever are very prominent
Go out.Accordingly, it is thus proposed that the scheme of copper olse is reduced using superconductor, still, the highest of present superconductor is critical
Temperature is 150K, i.e., -123 DEG C, and the superconductor to work under ultralow temperature is obviously not suitable for promoting and applying.
On the other hand, the used material of stator core is mainly traditional silicon steel sheet, due to the change frequency of magnetic flux in stator core
Rate is directly proportional to the rotating speed of motor, and specific loss consumption is proportional to 1.3~1.5 powers of frequency, so silicon steel sheet group is into stator iron
The loss of the heart will be dramatically increased with the rise of frequency.According to measuring and calculating, in the case where frequency is 50Hz, magnetic flux density is 1.0 T, silicon steel
The loss of stator core is smaller, is only 1.4W/kg, with the rise of frequency, the loss of stator core also significantly raises.Work as frequency
It is increased to 1 kHz, when magnetic flux density is 1.0 T, the loss of silicon steel stator core increases to 102W/kg.For example, a rotating speed is
The motor of 60000r/min, when stator core changes of magnetic field frequency is 3000 r/min, the unit iron loss of motor will increase by 50~80
Times, to reduce the high-frequency loss of iron core, can use reduces the magnetic flux density in iron core or the method using low-loss core material.
From a structural point, existing permanent-magnet brushless DC electric machine should at least carry out significant improvement in terms of four：One
It is to change motor body in mechanical structure to separate the present situation used with controller, realizes permanent-magnet brushless DC electric machine and controller
Integral structure, fully phases out line between the two, strengthens its ease for use, this is also the necessarily hair of permanent-magnet brushless DC electric machine
Exhibition trend；Second, using the microcontroller rather than DSP of efficient double-core on circuit topological structure, motor height can be both ensured in speed
The running effectively control, while device cost can be substantially reduced again in real time of speed；Third, change on heat dissipation topological structure using biography
The traditional design of system FR4 printed substrates, by using the printed wiring board of high duty metal base, improves external heat transfer
Rate, the heat sink temperature without fan, directly reduction high-power V metal-oxide-semiconductor；Fourth, changing hall position sensor passes through manual setting
Assembling is embedded in the custom of iron core winding, is directly welded in the printed wiring board of Metal Substrate, this is simplified brushless, permanently
Direct current generator production technology, improves the preferable measure of Hall orientation sensing accuracy and production efficiency.
Obviously, after motor body is combined into one with controller, while the problem of new is derived again：First, how to allow motor sheet
Effective combination on space structure is realized between body and controller；Asked second, how to dispose both integrated rear serious heat dissipations
Topic；Third, by what method realize it is energy-saving most saved with reaching system, the effect of total optimization.
Technical solution
For this reason, the present invention proposes a kind of amorphous alloy core body permanent-magnet brushless DC electric machine, it is adapted to rated power not small
In the permanent-magnet brushless DC electric machine of 500W.
Its technical solution is specific as follows：
A kind of amorphous alloy core body permanent-magnet brushless DC electric machine, is made of, motor motor body and controller two parts
Body part includes motor upper cover, motor bottom end cover, motor output shaft, excessively outlet hole, line guard ring, axle sleeve, upper skeleton, sending down the fishbone
Frame, stator coil, stator core body, rotor core body, Nd-Fe-B permanent magnetic block, upper bearing (metal), lower bearing, fixed screw, controller
Part include aluminum metal-matrix printed wiring board, control cable, control with double-core microcontroller, motor driving with power VMOS tube,
Position sensing Hall element A, Hall element B, Hall element C, it is characterized by：The amorphous alloy core body permanent magnetism without
Brushless motor is electromechanical integrated structure, and motor body and controller are encapsulated in motor upper cover and motor bottom end cover,
The stator core body is formed by stacking by the multi-disc amorphous alloy film for being provided with line embedding groove, and is fixed on by upper skeleton with
In the supporter of skeleton composition, each line bag of the stator coil of coiling aftershaping is mutually embedding respectively to be installed on upper skeleton and lower skeleton
On, the rotor core body is formed by stacking by non-crystaline amorphous metal rotor core sheet, passes through four convex annulars of rotor core on piece
After head realizes multi-disc overlapping positioning, then position pilot holes by four thereon and be fixed into rotor core body through exhausted magnetic screw,
Eight v-shaped openings are evenly distributed with rotor core body punching edge, the Nd-Fe-B permanent magnetic block of eight pieces of tiles is embedded in respectively
On rotor core body edge between two adjacent v-shaped openings, one fluting of tight fit installation on the motor output shaft
Axle sleeve, rotor core body by rotor core centre bore be installed on fluting axle sleeve on, aluminum metal-matrix printed wiring board respectively by
The layer printed circuit board on upper strata, middle thermally conductive insulating layer and support aluminum metal cylinder composition, its thermally conductive insulating layer pass for high fever
The epoxy resin of the property led inorganic filler, it makes layer printed circuit board be closely bonded integrally with support aluminum metal cylinder, is propping up
Support and external screw thread has been engraved on the round surface of aluminum metal cylinder, metal core printed circuit board is supported on aluminum metal cylinder by it
Screw into the inner thread in motor bottom end cover, then by screw through the fixation in aluminum metal-matrix printed wiring board
The technology hole of screw hole and upper skeleton is fixedly connected, and the copper foil on the layer printed circuit board is etched into electric machine controller electricity
Road, Surface Mount and is welded with power VMOS tube, double-core microcontroller, Hall element A, Hall element B, Hall element C respectively, is supporting
There is the Archimedian screw shape vent rib of protrusion at the back side of aluminum metal cylinder.
Motor upper cover, motor bottom end cover are aluminum alloy die casting, respectively have one on motor upper cover and motor bottom end cover
Outlet hole, control cable one end are welded in aluminum metal-matrix printed wiring board, and the other end passes through the mistake being mutually embedded in outlet hole
Drawn after line guard ring, be fixedly mounted and be integrally formed by four fixed screws respectively between motor upper cover and motor bottom end cover.
It is eight core cables to control cable, and it is positive and negative to represent positive pole, ground wire, electric motor starting/stopping, motor respectively
Turn, brake signal, speed governing ,+5V, common port, wherein, the external electric motor starting/shutdown switch of electric motor starting/stop line, motor is just
The external motor positive and inverse switch of reversed line, the external braking signal switch pedal of brake signal line, the speed governing ,+5V, common port
External speed control crank.
Double-core microcontroller Surface Mount is welded at pad, and double-core microcontroller is in addition to carrying capture/comparing unit kernel, at the same time
It is integrated with for high-speed multiply division arithmetic unit and for coordinating the digital computing unit kernel of rotating vector, Hall member
Part A insertings are welded at the Hall element A welding holes of aluminum metal-matrix printed wiring board, Hall element B insertings are welded on aluminum metal-matrix
At the Hall element B welding holes of printed wiring board, Hall element C insertings be welded on the Hall element C of aluminum metal-matrix printed wiring board
At welding hole, after Hall element A, Hall element B, the pin of Hall element C each pass through aluminum metal-matrix printed wiring board, its magnetic strength
Body is answered just mutually to be embedded in the gap of three adjacent line embedding grooves of stator core body, wherein the magnetic induction face of Hall element B and Hall
Element A, the magnetic induction plane of Hall element C on the contrary, when rotor core body rotates, the Nd-Fe-B permanent magnetic block of tile respectively close to
By the magnetic induction plane of Hall element A, the magnetic induction reverse side of Hall element B, Hall element C magnetic induction plane.
There is step in the upper end cover of support upper bearing (metal) on the motor upper cover, have shaft outlet hole and support on motor bottom end cover
Step in the bottom end cover of lower bearing, a central circular hole, motor output are provided with the middle position of aluminum metal-matrix printed wiring board
The centre bore rear enclosure of one end of axis through aluminum metal-matrix printed wiring board connects bearing, and upper bearing (metal) is inlaid into step in upper end cover again
Interior, the other end socket lower bearing of motor output shaft, lower bearing is inlaid into bottom end cover in step, and motor output shaft is then under
Shaft outlet hole on end cap stretches out.
The stator coil is made of 12 line bags altogether, and each line bag is formed with anaerobic copper enameled wire coiling respectively.
Technique effect
Amorphous alloy core body permanent-magnet brushless DC electric machine proposed by the present invention has the advantages that：
1st, amorphous alloy core body permanent-magnet brushless DC electric machine of the present invention, in mechanical structure, it changes permanent magnetism
Brshless DC motor is installed separately with controller, reconnects the conventional mounting pattern used, but by motor body and controller, hold
Row mechanism takes integral structure, instead of various exterior control harness, eliminates conventional permanent magnet brushless direct current generator and externally provide
Three U, V, W phase lines and five position sensor device control lines, enhance its reliability, realize system and most save, total optimization.
2nd, amorphous alloy core body permanent-magnet brushless DC electric machine of the present invention, the substitution silicon steel sheet application of its non-crystaline amorphous metal
In electric machine stator iron and rotor core, the efficiency and power density of motor can be largely improved, reduces iron loss；
By using the line bag of anaerobic copper enameled wire coiling stator coil to reduce copper loss, make the energy conservation and consumption reduction effects of motor obvious.
3rd, on heat dissipation topological structure, the controller solved well by using aluminum metal-matrix printed wiring board is first
Connectivity problem of the part in printed wiring board；The combination side being integrated by aluminum metal-matrix printed wiring board and the rotation of motor metal shell
Formula, improves thermal conductivity factor, solves the heat dissipation problem of the power VMOS tube of controller.
4th, the efficient double-core microcontroller substitution dsp chip by using low cost, solves motor High-speed Control and core
Contradiction between piece price, greatly reduces manufacture cost.
5th, the position sensor Hall element of traditional permanent-magnet brushless DC electric machine, is sealed by manual setting, resin
In stator core gap, its pin is externally drawn by line again, and usually positioning is inaccurate, and the present invention is directly by Hall element
Pin is welded in the printed wiring board of electric machine controller, and position sensing positional accuracy is high, and uniformity is good, is a kind of brand-new
Position sensor localization method.
6th, in the case of same output power, amorphous alloy core body permanent-magnet brushless DC electric machine of the present invention can
Obtain excellent energy-saving characteristic, its volume only has the 60% of conventional motors, and weight only has 75%, intrinsic in vortex and material
Magnetic hystersis loss can decline 20% or so.
Obviously, amorphous alloy core body permanent-magnet brushless DC electric machine of the present invention, be no longer a kind of monotechnics or
The alternative and upgrading of the effective material of simple motor, but a kind of energy conservation measure of synthesis and brand-new control topologies set.
Brief description of the drawings
Fig. 1 amorphous alloy core body permanent-magnet brushless DC electric machine forward directions explosive view one；
Fig. 2 amorphous alloy core body permanent-magnet brushless DC electric machine forward direction outline drawings；
The reverse outline drawing of Fig. 3 amorphous alloy core body permanent-magnet brushless DC electric machines；
Fig. 4 removes the positive 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 microcontroller；
Fig. 9 amorphous alloy core body permanent-magnet brushless DC electric machine backlashes figure four；
Figure 10 amorphous alloy core body permanent-magnet brushless DC electric machine forward directions explosive view five.
Label declaration：
1 motor upper cover, 2 motor bottom end cover
3 motor output shaft, 4 fixed screw
5 control 6 aluminum metal-matrix printed wiring board of cable
7 power VMOS tube, 8 double-core microcontroller
9 Hall element A, 10 Hall element B
11 Hall element C, 12 stator coils
13 upper skeleton, 14 lower skeleton
15 stator core body, 16 rotor core body
17 Nd-Fe-B permanent magnetic block, 18 upper bearing (metal)
19 lower bearing, 20 outlet hole
21 annular plush coppers 22 position pilot hole
24 external screw threads
25 pad, 26 Hall element A welding holes
27 Hall element B welding holes, 28 Hall element C welding holes
29 rotor core centre bore, 30 Archimedian screw shape vent rib
Step in 32 bottom end cover of step in 31 upper end covers
33 cross 34 technology hole of line guard ring
35 v-shaped opening, 36 shaft outlet hole
37 line embedding groove, 38 central circular hole
39 axle sleeve, 40 fixed screw holes
Embodiment
The present invention is as shown in Figures 1 to 10.
Illustrate specific embodiments of the present invention below in conjunction with the accompanying drawings.
A kind of amorphous alloy core body permanent-magnet brushless DC electric machine, is made of, motor motor body and controller two parts
Body part is included on motor upper cover 1, motor bottom end cover 2, motor output shaft 3, motor upper cover 1 and motor bottom end cover 2
Outlet 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, Nd-Fe-B permanent magnetic block 17, upper bearing (metal) 18, lower bearing 19, fixed screw 4, controller part include aluminum metal-matrix track
Road plate 6, control cable 5, double-core microcontroller 8, power VMOS tube 7, position sensing Hall element A 9, Hall element B 10,
Hall element C 11, it is characterized by：The amorphous alloy core body permanent-magnet brushless DC electric machine is electromechanical integrated structure,
Motor body and controller are encapsulated in motor upper cover 1 and in motor bottom end cover 2, the stator core body 15 is embedding by being provided with
The multi-disc amorphous alloy film of wire casing 37 is formed by stacking, and is fixed on the supporter being made of upper skeleton 13 and lower skeleton 14
In, each line bag of the stator coil 12 of coiling aftershaping is mutually embedding respectively to be installed 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, passes through four of rotor core on piece
After annular plush copper 21 realizes multi-disc overlapping positioning, then the exhausted magnetic spiral shell by four positioning pilot holes 22 thereon through non-magnetizer
Silk is fixed into rotor core body 16, and eight v-shaped openings 35, eight pieces of tiles are evenly distributed with 16 punching edge of rotor core body
Nd-Fe-B permanent magnetic block 17 be embedded in respectively on 16 edge of rotor core body between two adjacent v-shaped openings 35, due to neodymium iron
Boron permanent magnets 17 are located on the outer surface of rotor core body 16, there is provided flow direction for radially, such Nd-Fe-B permanent magnetic block 17
Even air gap is region be directly facing, the particularly favorable orientation of Nd-Fe-B permanent magnetic block 17, therefore can obtain with preferable square-wave form
Air-gap field.
Tight fit installs the axle sleeve 39 of the fluting of a non-magnetizer, rotor core body 16 on the motor output shaft 3
It is installed on by rotor core centre bore 29 on the axle sleeve 39 of fluting, aluminum metal-matrix printed wiring board 6 is respectively by the printing on upper strata
Circuit layer, middle thermally conductive insulating layer and support aluminum metal cylinder composition, its thermally conductive insulating layer are filled out for high thermal conductivity is inorganic
The epoxy resin of thing is filled, it makes layer printed circuit board be closely bonded integrally with support aluminum metal cylinder, in support aluminum metal circle
External screw thread 24 is engraved on the round surface of cylinder, metal core printed circuit board 6 supports the outer spiral shell on aluminum metal cylinder by it
Line 24 is screwed in the inner thread in motor bottom end cover 2, then passes through the fixed screw in aluminum metal-matrix printed wiring board 6 with screw
Hole 40 is fixedly connected with the technology hole 34 on upper skeleton 13, the copper foil etching in the aluminum metal-matrix printed wiring board 6
Into electric machine controller circuit, Surface Mount and power VMOS tube 7, double-core microcontroller 8, Hall element A 9, Hall element are welded with respectively
B 10, Hall element C 11, have the Archimedian screw shape vent rib 30 of protrusion at the back side of support aluminum metal cylinder.
The motor upper cover 1, motor bottom end cover 2 are aluminum alloy die casting, and the proportion of aluminium is small, can mitigate motor
Weight, and aluminium category non-magnetizer, can reduce the leakage field of main field；Respectively there is an outlet hole on motor upper cover 1 and motor bottom end cover 2
20, one end of control cable 5 is welded in aluminum metal-matrix printed wiring board 6, and the other end, which passes through, to be mutually embedded in outlet hole 20
Draw after crossing line guard ring 33, be fixedly mounted into respectively by four fixed screws 4 between motor upper cover 1 and motor bottom end cover 2
One.
The control cable 5 is eight core cables, represents positive pole, ground wire, electric motor starting/stopping, electricity respectively
Machine rotating, brake signal, speed governing ,+5V, common port, wherein, the external electric motor starting/shutdown switch of electric motor starting/stop line,
The external motor positive and inverse switch of motor positive and inverse line, the external braking signal switch pedal of brake signal line, the speed governing ,+5V,
The external speed control crank of common port.
As it can be seen that external interface signal line provided by the present invention, it is external to eliminate conventional permanent magnet brushless direct current generator completely
Three U, V, W phase lines provided and five position sensor device control lines, it is only necessary to two power cords and five exterior control letters
Number, its reliability is enhanced, system is realized and most saves, total optimization.
8 Surface Mount of double-core microcontroller is welded at the pad 25 of aluminum metal-matrix printed wiring board 6, double-core microcontroller 8
In addition to carrying capture/comparing unit kernel, while it is integrated with for high-speed multiply division arithmetic unit and for coordinating rotation arrow
The digital computing unit kernel of amount, the Hall element A 9 insert the Hall element for being welded on aluminum metal-matrix printed wiring board 6
At A welding holes 26, the insertings of Hall element B 10 are welded at Hall element B welding holes 27, the insertings of Hall element C 11 are welded on Hall
At element C welding holes 28, Hall element A 9, Hall element B 10, the pin of Hall element C 11 are each printed through aluminum metal-matrix
After wiring board 6, its magnetic induction body is just mutually embedded in the gap of the adjacent line embedding groove 37 of stator core body 15 3, wherein Hall member
The magnetic induction face of part B 10 and Hall element A 9, the magnetic induction plane of Hall element C 11 on the contrary, when rotor core body rotates,
The Nd-Fe-B permanent magnetic block 17 of tile is respectively close to the magnetic induction plane by Hall element A 9, the magnetic strength of Hall element B 10
Answer the magnetic induction plane of reverse side, Hall element C 11.In contrast, the position sensor of traditional permanent-magnet brushless DC electric machine is suddenly
That element, is all by resin-encapsulated in stator core gap, its pin is externally drawn by line again, and shortcoming is to position not
Too precisely, slightly deviation will influence its positioning output signal, cause position error, the present invention directly welds Hall element pin
It is connected in the printed wiring board of electric machine controller, position sensing positional accuracy is high, is a kind of brand-new position sensor positioning
Method.
There is step 31 in the upper end cover of support upper bearing (metal) 18 on the motor upper cover 1, have shaft outlet hole on motor bottom end cover 2
36 and support lower bearing 19 bottom end cover in step 32, a center is provided with the middle position of aluminum metal-matrix printed wiring board 6
Circular hole 38,38 rear enclosure of central circular hole of one end through the aluminum metal-matrix printed wiring board 6 of motor output shaft 3 connect bearing 18, on
Bearing 18 is inlaid into 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, then motor output shaft 3 is stretched out from the shaft outlet hole 36 on bottom end cover 2.
The stator coil 12 is made of 12 line bags altogether, and each line bag uses oxygen-free copper respectively（OFC）Enameled wire coiling,
Compared with traditional enamel covered wire, oxygen-free copper-wire（OFC）Electrical conductivity be cathode copper 109.0%, resistivity ratio routine enameled wire
Smaller, welding performance, corrosion resisting property and cryogenic property are more preferable than conventional enameled wire, and particularly its hardness is small, flexible, offline
It is convenient, copper loss, more meaningful, oxygen-free copper-wire can be substantially reduced（OFC）Since the surface for making copper wire generates distinctive gold
Belong to structure, the surface of same root copper conductor is adapted to the pwm signal for transmitting 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, is not disturbed mutually.Although having selected oxygen-free copper-wire,
It is on the high side, but due to electromagnetic system magnetic flux density B high, with the same power permanent magnetic brushless dc motor using common enameled wire
Compare, the line bag number of turn can reduce nearly 10%, can save copper nearly 10% again in other words.
Here it is noted that the method for traditional electric machine controller power device heat dissipation has two kinds, first, directly using
Copper foil printed wiring board radiates, that is, common FR4 printed substrates, but for electric machine controller, high current
FR4 printed substrates are caused to be difficult to bear high heat with powerful drive circuit, because the thermal conductivity of FR4 printed substrates
Rate is only 0.36W/ (m.K), and thermal coefficient of expansion is 13~17ppm/K；Second, power VMOS tube is directly directly installed on height
Heat conduction and heat radiation on piece, is externally radiated by the fin on heat sink or rib, it is clear that is increased newly again in a motor body structure
Be difficult to implement come the scheme that auxiliary power device radiates by multiple heat sinks, this namely why existing brshless DC motor
Body separates the main reason for independent with controller.
The novel part of creating of the present invention is：A kind of unique heat dissipation topological structure is devised, first, easily real
Motor body and the two-part effectively connection of controller are showed；Second, substantially increasing high fever inside controller is emitted into outside
Heat conductivity.Power VMOS tube 7 is mounted in aluminum metal-matrix printed wiring board 6, since support aluminum metal cylinder is the excellent of heat
Good conductive material, and support the back side of aluminum metal cylinder to have the Archimedian screw shape vent rib 30 of protrusion, therefore, electricity
When road works, concentration of local will not be presented in the heat that power VMOS tube 7 produces, its hot-fluid is by radial flowing, and aluminum metal
Base printed wiring board 6 supports the external screw thread 24 on aluminum metal cylinder to screw in the inner thread in motor bottom end cover 2 by it, and
An entirety is connected into, so that the high fever that power VMOS tube 7 produces can be emitted into outside quickly through motor bottom end cover 2, separately
On the one hand, since upper end cover 1 and bottom end cover 2 are to be connected to form an entirety by fixed screw, there is high thermal conductivity coefficient
Aluminum alloy die casting upper end cover 1 and 2 shared of the bottom end cover external heat dissipation task of motor, so as to expand radiating surface
Product.
To be produced during to prevent that thermal coefficient of expansion is different between different materials heat tilt caused by short circuit, the aluminum metal-matrix
The thermally conductive insulating layer of the centre of printed wiring board 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 be closely bonded with support aluminum metal cylinder.
The most important innovation of the present invention also resides in, and stator core body 15 and rotor core body 16 are folded using amorphous alloy film
The non-crystaline amorphous metal body formed is closed, its magnetic strong, soft magnet performance of non-crystaline amorphous metal is better than silicon steel sheet, moderate, greatly reduces whirlpool
Intrinsic magnetic hystersis loss in stream and material.Computer simulation emulation the results show that non-crystaline amorphous metal in the case of frequency 1KHz, it is non-
The core loss of peritectic alloy is 7.77w/kg, its eddy-current loss can decline 17%, and 58.8% is reduced than silicon steel stator core.
It is relatively thin for amorphous alloy film, it is very sensitive to mechanical stress, hold in stretching since local deformation amount is excessive
The characteristics of easy fracture, elongation percentage is very low, this invention takes following design, is processed for the ease of laser punching and shears and obtain
Excellent Frequency Power Loss characteristic, makes annealing treatment amorphous alloy iron core sheet, but brittleness after amorphous alloy iron core sheet annealing
It is larger, therefore in order to avoid, by the use of amorphous alloy core as main load-bearing structural member, especially pacifying stator core body 15 in structure
Dress is fixed in the supporter being made of upper skeleton 13 and lower skeleton 14, reduces tension force or bending stress pair to the full extent
The influence of 15 magnetic property of stator core body, the upper skeleton 13 and lower skeleton 14 use fire-retardant high heat-resistant engineering plastic.It is non-
When peritectic alloy lamination makees rotor core, the influence of centrifugal force is considered, therefore the annular plush copper of first pass through rotor core on piece four
21 realize multi-disc overlapping positioning, and the presence of annular plush copper 21 increases the frictional resistance between rotor core sheet at the same time, then lead to
The four circular positioning pilot holes 22 crossed thereon are fixed into rotor core body 16 through exhausted magnetic screw, to strengthen rotor core body
Integral strength.
In conclusion the substantial improvements of the present invention are：
1st, in mechanical structure, change motor body and separately manufacture and design with controller, install respectively, then pass through electric wire
The traditional mode that cable connection uses, but motor body and controller are taken into integral structure, it is adapted to rated power not small
In the permanent-magnet brushless DC electric machine of 500W, due to instead of various control harness, conventional permanent magnet brushless direct current generator is eliminated
Three required U, V, W phase lines and five hall position sensor device control lines, so that the exterior control cable drawn
For eight core cables, reliability is enhanced, improves ease for use, the system that realizes most saves and total optimization.
2nd, on effective material of motor manufacturing, silicon steel is substituted using non-crystaline amorphous metal, while be applied to electric machine stator iron
And rotor core, for non-crystaline amorphous metal compared with traditional silicon steel sheet, the coercivity of non-crystaline amorphous metal is the 1/7 of cold-rolled orientation silicon steel piece
Left and right, the area of the hysteresis curve institute envelope of non-crystaline amorphous metal are much smaller than cold-rolled orientation silicon steel piece, therefore the magnetic hysteresis damage of non-crystaline amorphous metal
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 silicon steel sheet three/
One.
3rd, in order to overcome the thin deficiency of non-crystaline amorphous metal crisp chip, present invention design is employed based on fire-retardant high-temperature resistant engineering
The upper skeleton and lower skeleton that plastics are formed are as stator core supporter stator core body is fixedly mounted.
4th, by using anaerobic copper enameled wire coiling stator coil bag to reduce copper loss, kelvin effect is greatly reduced,
Make the energy conservation and consumption reduction effects of motor obvious, while improve the efficiency and power density of motor.
5th, on heat dissipation topological structure, solves controller component in track by using aluminum metal-matrix printed wiring board
The connectivity problem of road plate, the design being integrated by aluminum metal-matrix printed wiring board and the rotation of motor metal shell, improves its heat
Conducting power, solve the heat dissipation problem of power VMOS tube, and realize effective connection of controller and motor body.
6th, using the expensive dsp chip of double-core microcontroller substitution, double-core microcontroller built-in Hall position detection software module,
Protection module and rotating vector computing module, solve contradiction of the motor at a high speed between effectively real-time control and chip price, greatly
Reduce manufacture cost greatly.
7th, 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 gap, realizes the positioning side of the good brand-new sensing rotor current location of uniformity
Case.
8th, 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 unexpected 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%, intrinsic magnetic hystersis loss can decline 20% or so in vortex and material, copper loss
Decline 18%.
In short, amorphous alloy core body permanent-magnet brushless DC electric machine of the present invention, be no longer by monotechnics or
The permanent-magnet brushless DC electric machine of conventional method design, but one kind combines electrical material, machine-building, controls topology multidisciplinary
The system integration of technology.Undoubtedly, this be a kind of good reliability, using it is simple, be widely used, highly promising novel permanent magnetic is brushless
Direct current generator, is adapted to the application in military project and high-end electronic product and market, is existing permanent-magnet brushless DC electric machine and motor control
The renewal product of device.
Claims (5)
1. a kind of amorphous alloy core body permanent-magnet brushless DC electric machine, is made of motor body and controller two parts, motor sheet
Body portion includes motor upper cover（1）, motor bottom end cover（2）, motor output shaft（3）, outlet 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
Iron 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 microcontroller（8）, power VMOS tube（7）, Hall element A（9）, Hall element B（10）、
Hall element C（11）, it is characterised in that：
The amorphous alloy core body permanent-magnet brushless DC electric machine is electromechanical integrated structure, and motor body and controller seal
Mounted in motor upper cover（1）With motor bottom end cover（2）Interior, described stator core body（15）By being provided with line embedding groove（37）Multi-disc
Amorphous alloy film is formed by stacking, and is fixed on by upper skeleton（13）And lower skeleton（14）In the supporter of composition, after coiling
Molding stator coil（12）Each line bag mutually embedding be installed on upper skeleton respectively（13）With lower skeleton（14）On, the rotor
Iron core（16）It is formed by stacking by non-crystaline amorphous metal rotor core sheet, passes through four annular plush coppers of rotor core on piece（21）Realize
After multi-disc overlapping positioning, then pass through four positioning pilot holes thereon（22）Rotor core body is fixed into through exhausted magnetic screw
（16）, rotor core body（16）Eight v-shaped openings are evenly distributed with punching edge（35）, the Nd-Fe-B permanent magnetic of eight pieces of tiles
Block（17）Rotor core body is embedded in respectively（16）Two adjacent v-shaped openings on edge（35）Between, motor output
Axis（3）Upper tight fit installs the axle sleeve of a fluting（39）, rotor core body（16）Pass through rotor core centre bore（29）Installation
In the axle sleeve of fluting（39）On, aluminum metal-matrix printed wiring board（6）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, it makes print
Brush circuit layer closely bonds integrally with support aluminum metal cylinder, has been engraved on the round surface of support aluminum metal cylinder outer
Screw thread（24）, aluminum metal-matrix printed wiring board（6）The external screw thread on aluminum metal cylinder is supported by it（24）Screw under motor
End cap（2）In inner thread in, then with screw pass through aluminum metal-matrix printed wiring board（6）On fixed screw holes（40）With it is upper
Skeleton（13）On technology hole（34）It is fixedly connected, the aluminum metal-matrix printed wiring board（6）On copper foil be etched into
Electric machine controller circuit, Surface Mount and is welded with power VMOS tube respectively（7）, double-core microcontroller（8）, Hall element A（9）, Hall
Element B（10）, Hall element C（11）, have the Archimedian screw shape cooling fin of protrusion at the back side of support aluminum metal cylinder
Bar（30）；
The double-core microcontroller（8）Surface Mount is welded in aluminum metal-matrix printed wiring board（6）Pad（25）Place, double-core microcontroller
（8）In addition to carrying capture/comparing unit kernel, while it is integrated with for high-speed multiply division arithmetic unit and for coordinating to rotate
The digital computing unit kernel of vector, the Hall element A（9）Inserting is welded on aluminum metal-matrix printed wiring board（6）Suddenly
That element A welding holes（26）Place, Hall element B（10）Inserting is welded on Hall element B welding holes（27）Place, Hall element C（11）Insert
Welding equipment is connected on Hall element C welding holes（28）Place, Hall element A（9）, Hall element B（10）, Hall element C（11）Pin it is each
From through aluminum metal-matrix printed wiring board（6）Afterwards, its magnetic induction body is just mutually embedded in stator core body（15）Three adjacent embeddings
Groove（37）Gap, wherein Hall element B（10）Magnetic induction face and Hall element A（9）, Hall element C（11）Magnetic strength
Plane is answered on the contrary, rotor core body（16）During rotation, the Nd-Fe-B permanent magnetic block of tile（17）Respectively close to passing through Hall element A
（9）Magnetic induction plane, Hall element B（10）Magnetic induction reverse side, Hall element C（11）Magnetic induction plane.
2. amorphous alloy core body permanent-magnet brushless DC electric machine according to claim 1, it is characterised in that：Motor upper cover
（1）, motor bottom end cover（2）It is aluminum alloy die casting, motor upper cover（1）With motor bottom end cover（2）On respectively have an outlet hole
（20）, control cable（5）One end be welded on aluminum metal-matrix printed wiring board（6）On, the other end passes through and is mutually embedded in outlet hole
（20）In cross line guard ring（33）After draw, motor upper cover（1）With motor bottom end cover（2）Between pass through fixed screw respectively
（4）It is fixedly mounted.
3. amorphous alloy core body permanent-magnet brushless DC electric machine according to claim 1 or 2, it is characterised in that：Described
Control cable（5）For eight core cables, positive pole, ground wire, electric motor starting/stopping, motor positive and inverse, braking are represented respectively
Signal, speed governing ,+5V, common port, wherein, the external electric motor starting/shutdown switch of electric motor starting/stop line, outside motor positive and inverse line
Connect motor positive and inverse switch, the external braking signal switch pedal of brake signal line, the speed governing, the external speed governing of+5V, common port
Handle.
4. amorphous alloy core body permanent-magnet brushless DC electric machine according to claim 1, it is characterised in that：On the motor
End cap（1）On have support upper bearing (metal)（18）Upper end cover in step（31）, motor bottom end cover（2）On have shaft outlet hole（36）And support
Lower bearing（19）Bottom end cover in step（32）, in aluminum metal-matrix printed wiring board（6）Middle position be provided with one center circle
Hole（38）, motor output shaft（3）One end pass through aluminum metal-matrix printed wiring board（6）Central circular hole（38）Rear enclosure connects bearing
（18）, upper bearing (metal)（18）Step in upper end cover is inlaid into again（31）It is interior, motor output shaft（3）The other end socket lower bearing
（19）, lower bearing（19）It is inlaid into step in bottom end cover（32）In, motor output shaft（3）Then from bottom end cover（2）On shaft
Hole（36）Stretch out.
5. amorphous alloy core body permanent-magnet brushless DC electric machine according to claim 1, it is characterised in that：The stator
Coil（12）It is made of altogether 12 line bags, each line bag is formed with anaerobic copper enameled wire coiling respectively.
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| CN201610818648.9A CN106208545B (en) | 2016-09-13 | 2016-09-13 | Amorphous alloy core body permanent-magnet brushless DC electric machine |
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| 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 |
| JP6723201B2 (en) * | 2017-07-13 | 2020-07-15 | 日立オートモティブシステムズ株式会社 | Electric drive device and electric power steering device |
| CN107317452B (en) * | 2017-08-21 | 2019-01-15 | 彭希南 | Integrated permanent magnetism brushless direct current hub motor |
| 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 |
| CN108730218B (en) * | 2018-06-04 | 2020-02-04 | 彭希南 | Full-automatic frequency-variable speed-adjustable ventilating fan |
| CN108667226B (en) * | 2018-06-04 | 2020-02-14 | 彭希南 | Flat three-phase permanent magnet brushless direct current motor core |
| EP3595137A1 (en) * | 2018-07-12 | 2020-01-15 | Levitronix GmbH | Electromagnetic rotary drive and rotary device |
| JP7083298B2 (en) * | 2018-09-28 | 2022-06-10 | 本田技研工業株式会社 | Motor structure and vehicle |
| 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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| JP2007097375A (en) * | 2005-09-30 | 2007-04-12 | Japan Servo Co Ltd | Rotation speed detection device for brushless dc motor |
| JP2009065746A (en) * | 2007-09-05 | 2009-03-26 | Teikoku Electric Mfg Co Ltd | Canned motor drive system |
| CN202178695U (en) * | 2011-08-05 | 2012-03-28 | 浙江尤奈特电机有限公司 | Permanent magnet brushless DC motor |
| CN205178778U (en) * | 2015-10-29 | 2016-04-20 | 徐州兴特尔电子科技有限公司 | Built -in control system motor structure |
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