CN107689699A - A kind of permanent-magnet brushless DC electric machine of novel printing winding - Google Patents

Abstract

The invention discloses a kind of permanent-magnet brushless DC electric machine using novel printing winding, it includes the p-m rotor of stator and axial charging made of multilayer board, wherein stator prints winding scheme per phase winding using quadrangle, by this printing winding, the axial dimension and cost of manufacture of motor are substantially reduced.Compared to traditional printed motor, the quadrangle printing winding scheme that the present invention uses eliminates the invalid winding in end, improves motor operation efficiency, reduce motor temperature rise.And its counter potential waveform is in sine wave, it is easy to use vector control mode controlled motor.

Description

A new permanent magnet brushless DC motor with printed windings

technical field

The invention belongs to the technical field related to motor design, in particular to a permanent magnet brushless DC motor with novel printed windings.

Background technique

Most of the traditional permanent magnet brushless DC motors are radial field motors, and the stators are composed of coils and iron cores. The motors are bulky and heavy. More consumption and higher cost.

The winding of the printed winding motor is different from the coil winding of the traditional motor. It is printed on the copper foil board through chemical methods such as corrosion method, electrochemical deposition method, and electrochemical transfer method. The permanent magnet brushless DC motor with printed winding breaks through the limitations of the traditional motor in terms of structural design. The motor adopts the axial magnetic field direction. Since the stator core of the traditional motor does not need to be used, the volume and weight of the motor can be greatly reduced, and the efficiency can be improved. The operating efficiency and overload capacity of the motor; in terms of intelligent control, remote intelligent control can be realized; at the same time, there is no stator winding off-line process in the production process of the motor, and the production cost is lower than that of traditional brushless DC motors. Therefore, in terms of overall performance, superior to conventional motors.

The working principle of the printed winding permanent magnet brushless DC motor is the same as that of the traditional permanent magnet brushless DC motor. It is characterized by large starting torque, wide speed range and high operating efficiency. The key to the design of the printed winding permanent magnet brushless DC motor is the connection method of the stator printed circuit board winding. The stator of the printed circuit board is connected by concentric windings. The conductors of this concentric winding are connected by arc-shaped end wires. This arc-shaped end wire has the advantages of large copper consumption, no torque output, increased motor loss, and increased motor temperature. Upgrading disadvantages. There are also literatures that arrange printed circuit board windings in the form of wave windings, but arc-shaped terminal wires must still be used to connect conductors. In addition, with the stator printed circuit board in the form of concentric winding and wave winding, the motor back EMF waveform is in the form of a square wave, which cannot achieve the superior performance of the motor controller's sine wave control.

Contents of the invention

The purpose of the present invention is to solve the above-mentioned technical problems existing in the prior art, and the present invention provides a novel printed winding design scheme based on quadrilateral conductors, which can reduce the volume and manufacturing cost of permanent magnet brushless DC motors and improve operating efficiency , and the back EMF waveform can be designed as a sine wave, which facilitates the realization of high-performance vector control and improves the performance and work efficiency of the motor.

In order to solve the above problems, the present invention provides the following technical solutions:

A new permanent magnet brushless DC motor with printed windings, including a motor casing, a stator fixed inside the motor casing, and a rotor assembly that rotates through the motor casing; the stator is a printed circuit board structure, including a working conductor layer and connecting Conductor layer; the winding units in the working conductor layer are arranged in a quadrilateral, each pole and each phase winding of the stator is formed by a plurality of quadrilateral winding units in series, and each phase winding under different numbers of poles can be connected in series or in parallel by connecting the conductor layer form connection to form a phase winding.

Preferably, there are two working conductor layers, the two working conductor sides of the quadrilateral winding unit in the left L shape are located on one of the working conductor layers, and the two working conductor sides of the quadrilateral winding unit in the right L shape are located on the other On one working conductor layer, the outer ends of the two working conductor sides of the left L shape and the two working conductor sides of the right L shape are connected in series through the outer diameter via holes, and the inner ends are connected in series through the inner diameter via holes, thus forming a quadrilateral winding unit, the winding structure only needs two working conductor layers to print the windings of each pole and each phase on the printed circuit board, which can reduce the thickness of the stator, simplify the processing technology and reduce the manufacturing cost. Among them, the distance between the intersection point of the two working conductor sides in the left L shape and the intersection point of the two working conductor sides in the right L shape in the quadrilateral winding unit is not greater than the pole pitch of the motor, which is beneficial to realize the motor controller sine Wave control, easy to control the motor by vector control.

Further, the connecting conductor layer includes several connecting conductor sides, each pole and each phase winding of the stator includes a positive terminal and a negative terminal, and the negative terminal of each pole and each phase winding is connected to the positive terminal of the adjacent pole winding of the phase through the connection Conductor side electrical connection; in this scheme, the windings of each pole and each phase are connected in series, that is, the number of parallel branches per phase is 1. The above-mentioned winding configuration method is one of the schemes, and the number of parallel branches per phase can also be greater than 1. Others Winding connection configurations are also within the scope of the patent.

The stator also includes a plurality of through-hole conductor columns perpendicular to the working conductor layer and the connecting conductor layer, the through-hole conductor columns are used for the two working conductors of the quadrilateral winding unit in a left L-shape and in a right-L shape The electrical connection between the two working conductor sides, and the electrical connection between the positive terminal and/or negative terminal of each pole and each phase winding and the connecting conductor side.

Preferably, the printed circuit board of the stator is also provided with a Hall position sensor. Of course, the Hall position sensor may not be used. The stator can be connected to a direct current or an alternating current. The stator includes a three-phase winding, and the three-phase winding The connection structure is the same. When the three-phase windings are combined, they are spatially different from each other by 120 degrees in electrical angle. There are three Hall position sensors, which are respectively installed at the centerline positions of the windings of each phase.

Wherein, the stator is formed by stacking multiple working conductor layers and multiple connecting conductor layers, each working conductor layer and each connecting conductor layer are flat structures, and there is an insulating substrate layer between each layer; the rotor assembly includes a drive The shaft and the first rotor and the second rotor fixed on the drive shaft, the middle part of the stator is provided with a central circular hole for the drive shaft to pass through, and the first rotor and the second rotor are respectively located on both sides of the stator; Both the first rotor and the second rotor include a rotor back iron and a sector-shaped permanent magnet array, and the number of permanent magnets contained in the permanent magnet array is an even number and at least two.

Wherein, the rotor back iron is made of laminated silicon steel sheets or a whole piece of material with magnetic permeability, and the permanent magnet material can be ferrite, samarium cobalt, neodymium iron boron and other permanent magnet materials or the above three materials A combination of permanent magnets surface-mounted or embedded on the rotor back iron. The permanent magnets of the first rotor are arranged relative to the permanent magnets of the second rotor such that the magnetic flux lines pass through the stator in a direction perpendicular to the plane of the stator, and the adjacent permanent magnets N pole and S pole Polarity staggered distribution, that is, NS-SN distribution.

The stator and the rotor assembly can be configured as an outer stator/inner rotor or outer rotor/inner stator structure, or as a single stator/single rotor, single stator/double rotor, double stator/single rotor, double stator/ Three-rotor, three-stator/double-rotor structure. The motor can be used as a pure generator, pure electric or combined generator-electric operation.

Compared with prior art, the beneficial effect of the present invention:

A permanent magnet brushless DC motor with a novel printed winding structure according to the present invention, in which the winding of each phase of the stator adopts a quadrilateral printed winding scheme. Through this printed winding, the axial size and manufacturing cost of the motor are greatly reduced. Compared with For the stator of the traditional arc-shaped end wire printed winding, the invention cancels the invalid winding at the end, reduces the copper consumption, and reduces the temperature rise of the motor at the same time; and its back EMF waveform is sinusoidal, which is convenient to control the motor by vector control.

Description of drawings

Fig. 1 is the permanent magnet brushless DC motor of novel printed winding structure involved in the present invention, wherein an assembly drawing of an implementation form;

Figure 2 is a three-dimensional perspective view of the stator printed winding shown;

Figure 3 is a view of the stator shown in Figure 2 with one phase winding removed;

Fig. 4 is a view of the stator shown in Fig. 2, wherein the two-phase winding is deleted;

Figure 5 is a plan view of the stator printed winding shown;

Figure 6 is a preferred arrangement of the stator printed windings shown.

detailed description

Below in conjunction with accompanying drawing and embodiment of description, specific embodiment of the present invention is described in further detail:

Figure 1 shows an embodiment of the invention. The new permanent magnet brushless DC motor with printed winding structure includes: two motor casings 1 and 7, a drive shaft 5, two rotor back irons 4 and 6, two sets of axially magnetized sector permanent magnet arrays 3 and 8, Printed circuit board stator 2, bearing 9.

Still referring to Fig. 1, there are four permanent magnets each in the permanent magnet arrays 3 and 8, and each permanent magnet is magnetized along the axial direction, and the permanent magnet materials can be permanent magnet materials such as ferrite, samarium cobalt, neodymium iron boron or With the combination of the above three materials, the permanent magnet arrays 3 and 8 can be respectively fixed on the rotor back irons 4 and 6 in a surface-mounted or embedded manner. The permanent magnet array 3 and the rotor back iron 4 constitute the first rotor, the permanent magnet array 8 and the rotor back iron 6 constitute the second rotor, and the arrangement of the permanent magnets of the first rotor relative to the permanent magnets of the second rotor needs to make the magnetic flux lines Passing through the stator along the direction perpendicular to the flat structure of the stator printed circuit board, the adjacent permanent magnets N poles and S poles are distributed alternately, that is, NS-SN distribution. Of course, the permanent magnet arrays 3 and 8 can also be configured with other numbers of magnetic poles, such as including two, six, eight, sixteen or any other even number of magnetic poles that can be manufactured.

The first rotor and the second rotor are assembled together through the drive shaft 5 , and the two ends of the drive shaft are fixed on the two motor casings 1 and 7 through bearings 9 .

Combining the three-dimensional diagrams of the printed stator windings in Figure 1 and Figure 2, the stator printed circuit board 2 is a sheet-like multilayer structure, and its outer edge is octagonal, and it can also be circular, square or other shapes suitable for certain specific applications . The number of layers of the stator printed circuit board 2 is 5, and of course other configurations with any integer number of layers such as 2, 4, and 6 layers can also be used. In this preferred embodiment, the upper two layers are the working conductor layers, the windings of the first layer are the two working conductor sides in the shape of "<" (left L shape) in the quadrilateral winding unit, and the second layer is the quadrilateral winding There are two working conductor sides in the shape of ">" (right L shape) in the unit, and the upper and lower two working conductor layers are electrically connected through the via holes (inner diameter via hole, outer diameter via hole) existing in the inner and outer diameters, where the intersection of the left L-shaped conductors The distance between the intersection point and the right L-shaped conductor is not greater than the pole distance of the motor. In this preferred embodiment, the distance between the intersection point of the left L-shaped conductor and the intersection point of the right L-shaped conductor is an integer pole pitch, which is equal to the pole pitch of the motor. The third, fourth, and fifth layers are connecting conductor layers, and the negative terminal of each phase of the quadrilateral winding of each pole is electrically connected with the positive terminal of the quadrangular winding of the adjacent pole of the phase through the connecting conductor sides of the third, fourth, and fifth layers, that is, every The quadrilateral winding conductors of each phase of the poles are connected in series, and the number of parallel branches is 1. Among them, there are 48 quadrilateral coils, forming three-phase four-pole. The selection of the above-mentioned winding connection mode, quantity and pole pair number is only one of the preferred implementation solutions, and other winding connection modes, quantity and pole pair number selection are also within the protection scope of the patent.

Figure 2 shows a perspective view of the three-phase printed winding of the stator, 1A, 1B, and 1C are the A, B, and C three-phase left L-shaped working conductor sides of the first working conductor layer, and 2A, 2B, and 2C are the sides of the second working conductor layer A, B, C three-phase right L-shaped working conductor side. 11 represents that the printed winding is located at the connection conductor layer, that is, the connection conductor side of the third, fourth, and fifth layers, and is used to connect the negative terminal and the positive terminal of each pole and each phase winding. Conductors in the first and second working layers, as well as conductors in the working layer and conductors in the connection layer, are electrically connected through via hole conductor posts 10 .

Figure 3 shows the layout of phase B and C windings after phase A is removed, where 1B and 1C are the left L-shaped working conductor sides of phase B and C of the first working conductor layer, and 2B and 2C are the second working conductor layer The right L-shaped working conductor side of the B and C phases, 10 is the via hole conductor post, and 11 is the connecting conductor side in the connecting conductor layer.

Figure 4 shows the layout of the C-phase winding after the A and B phases are removed, 1C is the left L-shaped C-phase working conductor side of the first working conductor layer, 2C is the right L-shaped C-phase of the second working conductor layer On the working conductor side, 10 is the via conductor, and 11 is the connecting conductor side in the connecting conductor layer. The connecting conductor side 11 does not have to be arranged as shown in the figure, and can be optimized according to the principles of copper saving and convenient drawing.

Fig. 5 shows the plan view of the stator printed winding, which illustrates the new winding form from another perspective, α, β, γ represent the effective conductors of the A, B, C three-phase quadrilateral winding cutting magnetic field, 11A, 11B, 11C represents the connecting conductor side in the A, B, C three-phase quadrilateral winding, that is, the end conductor. When the stator board needs to install the Hall position sensor, it can be installed at the respective centerline positions of the adjacent three-phase windings. In this preferred embodiment, three position sensors are placed at the dotted lines indicated by X, Y, Z.

Figure 6 shows a preferred arrangement of stator printed windings. This figure only shows the winding distribution of one phase. It has four working conductor layers. The conductors at the same position of different working conductor layers are connected in parallel through via holes. 1D represents the left L-shaped conductor side of the first working conductor layer, and 2D represents the second working conductor layer. The right L-shaped conductor side of the conductor layer forms a quadrilateral conductor coil with the L-shaped conductor side at the corresponding position of 1D. 3D represents the left L-shaped conductor side of the third working conductor layer, and 4D represents the right L-shaped conductor side of the fourth working conductor layer, which forms a quadrilateral conductor coil with the L-shaped conductor at the corresponding position of 2D. The quadrilateral conductors formed by the first and second working conductor layers are connected in parallel with the quadrilateral conductors at the same positions as the third and fourth working conductor layers through the via holes at both ends to increase the current value passed into the stator. 11 represents the connection conductor side of the connection conductor layer, that is, the end conductor, and 10 is the via hole conductor post.

The above description is only a preferred embodiment of the present invention, and does not make any limitation to the technical scope of the present invention, so any minor modifications, equivalent changes and modifications made to the above embodiments according to the technical essence of the present invention are still valid. It belongs to the scope of the technical solution of the present invention.

Claims (10)

1. A permanent magnet brushless DC motor with a new type of printed winding, including a motor casing, a stator fixed inside the motor casing, and a rotor assembly that rotates through the motor casing; the stator is a printed circuit board structure, including a working conductor layer and connect the conductor layer; it is characterized in that: the winding units in the working conductor layer are arranged in a quadrilateral shape, each pole and each phase winding of the stator is formed by a plurality of quadrilateral winding units connected in series, and each phase winding under different numbers of poles is connected by The conductor layers are connected in series or in parallel to form a phase winding. 2. The permanent magnet brushless DC motor with new printed windings according to claim 1, characterized in that: there are two working conductor layers, and the two working conductor sides of the quadrilateral winding unit in the left L shape are located in one of them On the working conductor layer, the right L-shaped two working conductor sides of the quadrilateral winding unit are located on another working conductor layer, and the intersection point of the two left L-shaped working conductor sides in the quadrilateral winding unit and the right L-shaped The distance between the intersection points of the two working conductor sides is not greater than the pole pitch of the motor. 3. The permanent magnet brushless DC motor with novel printed windings according to claim 2, characterized in that: the connecting conductor layer includes several connecting conductor sides, each pole and each phase winding of the stator includes a positive terminal and a negative terminal, each The negative terminal of each phase winding is electrically connected to the positive terminal of the adjacent pole winding of the phase through the connecting conductor side; The stator also includes a plurality of through-hole conductor columns perpendicular to the working conductor layer and the connecting conductor layer, the through-hole conductor columns are used for the two working conductors of the quadrilateral winding unit in a left L-shape and in a right-L shape The electrical connection between the two working conductor sides, and the electrical connection between the positive terminal and/or negative terminal of each pole and each phase winding and the connecting conductor side. 4. The permanent magnet brushless DC motor with novel printed windings according to claim 1, characterized in that: the printed circuit board of the stator is also provided with a Hall position sensor. 5. The new permanent magnet brushless DC motor with printed windings according to claim 1 or 4, characterized in that: the stator includes three-phase windings, the three-phase windings have the same connection structure, and the three-phase windings are connected to each other when they are combined. There is a 120-degree electrical angle difference between them in space. 6. The permanent magnet brushless DC motor with novel printed windings according to claim 1, characterized in that: the stator is formed by stacking a plurality of working conductor layers and a plurality of connecting conductor layers, each working conductor layer and each connecting conductor The layers are all flat structures, and there is an insulating substrate layer between each layer; The rotor assembly includes a drive shaft and a first rotor and a second rotor fixed on the drive shaft. A central circular hole is provided in the middle of the stator for the drive shaft to pass through. The first rotor and the second rotor are respectively located on the both sides of the stator; Both the first rotor and the second rotor include a rotor back iron and a sector-shaped permanent magnet array, and the number of permanent magnets contained in the permanent magnet array is an even number and at least two. 7. The permanent magnet brushless DC motor with new printed windings according to claim 6, characterized in that: the rotor back iron is made of laminated silicon steel sheets or a whole piece of material with magnetic permeability, and the permanent magnet The material can be ferrite, samarium cobalt, neodymium iron boron and other permanent magnet materials or a combination of the above three materials, and the permanent magnet is surface-mounted or embedded on the rotor back iron. 8. The permanent magnet brushless DC motor with novel printed windings according to claim 6, characterized in that: the permanent magnets of the first rotor are arranged in such a way relative to the permanent magnets of the second rotor that the magnetic flux The wires pass through the stator in a direction perpendicular to the plane of the stator, and the N poles and S poles of adjacent permanent magnets are distributed alternately. 9. The permanent magnet brushless DC motor with novel printed windings according to claim 6, characterized in that: the stator and the rotor assembly can be configured as an outer stator/inner rotor or an outer rotor/inner stator structure, also It can be set as single stator/single rotor, single stator/double rotor, double stator/single rotor, double stator/three rotor, triple stator/double rotor structure. 10. The permanent magnet brushless DC motor with novel printed windings according to claim 1, characterized in that the motor can be used for pure power generation, pure electric power or combined power generation and electric power operation.