CN111711303A - Hollow cup brushless DC motor with locking device - Google Patents

Abstract

The invention discloses a coreless brushless direct current motor with a locking device, which comprises a motor main body and the locking device, wherein the front part of the motor main body is provided with an output end, the rear part of the motor main body is provided with the locking device, the motor main body realizes the output of torque, rotating speed and power function indexes, the motor main body comprises a front end cover, a stator armature, a shell, a rotor and a rear end cover, the front end of the shell is provided with the front end cover, the rear end of the shell is provided with the rear end cover, the middle part of the shell is provided with the rotor, and the outside of the rotor is provided with the stator armature in a matching way. By optimizing the sizes of the motor, the rotor position sensor and the locking device and by the multifunctional design of the parts, the size of the motor is fully utilized, the axial and radial sizes of the motor are reduced, and the miniaturization and high power density of the product are realized.

Description

Hollow cup brushless DC motor with locking device

Technical Field

The invention relates to the technical field of motors, in particular to a coreless brushless direct current motor with a locking device.

Background

The hollow cup brushless motor belongs to a direct current permanent magnet servo micro special motor, and is mainly different from a common brushless direct current motor in that: the armature core is not provided with a tooth socket, and the motor winding is manufactured into a cup-shaped motor according to a special winding process. Compared with the traditional tooth socket motor, the motor has the following advantages: 1. the efficiency is high: the efficiency of the coreless motor is mostly over 70 percent, part of products are even close to 90 percent, and the efficiency of the traditional tooth-groove motor is below 70 percent under the same volume and weight; 2. small volume, light weight, high power and torque density: because the working efficiency is improved, the loss is reduced, the power density of the coreless motor is greatly improved, and compared with the traditional tooth socket type motor, the volume and the weight can be reduced by about 30 percent; 3. the control performance is good: the torque fluctuation caused by the non-tooth-groove effect is small, and the motor runs stably; the electromechanical time constant is low, the dynamic response is good, the inductance of the motor is very low, the conventional electrical time constant is within 0.1ms, the electromechanical time constant is about 2ms, the motor response is rapid, the control is accurate, and the motor is suitable for being applied to high-precision driving systems, such as the fields of communication, robots, security protection, aerospace, rudder control systems and the like.

At present, a power driving part for a rudder control servo system mainly comprises four functional parts, namely a speed reducer, a servo hollow cup motor, a position sensor, a brake and the like. The integration level is poor at present for above-mentioned four functions, and size and volume are too huge after the functional unit makes up, lead to steering wheel weight and volume to increase, influence steering wheel mechanical dynamic response, miniaturization, lightweight design. Furthermore, the steering engine axial structure is generally structurally distributed according to the following mode, the front end adopts a speed reducer, the middle section is a steering servo coreless brushless direct current motor which mainly comprises a stator armature, a rotor, an end cover, a casing, a bearing, a rotor position sensor and accessory parts, the tail part is an electromagnetic brake, and the power driving module with the braking function steering engine system is formed by combining and arranging the above modes. However, the radial and axial dimensions of the conventional electromagnetic brake are generally large, so that the axial dimension of a steering engine rotor shafting is lengthened, the rigidity of a rotor system is easily deteriorated, particularly, the steering engine is subjected to vibration, noise and unstable control when the rotor runs at a high speed, and the key deterioration of the steering engine such as dynamic response, precision and reliability is further caused. On the other hand, the conventional brake has the maximum rotation speed limit, and the brake rotation speed is generally below 8000 rpm. In summary, the conventional structure of the reducer, the motor, the brake and the like arranged in the axial direction of the module components is difficult to meet the index requirements of the rudder control servo system such as integration, miniaturization, multifunction, light weight, miniaturization, high dynamic response, high reliability and the like.

Disclosure of Invention

The invention aims to provide a coreless brushless direct current motor with a locking device aiming at the defects of the prior art.

In order to solve the technical problems, the following technical scheme is adopted:

a coreless brushless DC motor with a locking device comprises a motor main body (1) and the locking device (3), wherein the front part of the motor main body (1) is provided with an output end, the rear part of the motor main body (1) is provided with the locking device (3),

the motor main body (1) realizes the output of functional indexes of torque, rotating speed and power, and comprises a front end cover (10), a stator armature (30), a machine shell (40), a rotor (50) and a rear end cover (60), wherein the front end of the machine shell (40) is provided with the front end cover (10), the rear end of the machine shell (40) is provided with the rear end cover (10), the middle part of the machine shell (40) is provided with the rotor (50), and the stator armature (30) is arranged outside the rotor (50) in a matching manner;

the locking device (3) releases the armature after a braking instruction occurs to the motor, and realizes an emergency braking function on the high-speed running rotor, the locking device comprises a brake ring (35), the armature (34) and a magnetic yoke (32), the armature (34) is positioned between the brake ring (35) and the magnetic yoke (32), and the armature (34) moves towards or away from the brake ring (35) to realize braking or unlocking of the motor rotor;

and a suction gap is arranged between the armature (34) and the magnetic yoke (32).

Furthermore, the coreless brushless direct current motor with the locker further comprises a rotor position sensor assembly (2), wherein the rotor position sensor assembly (2) is used for recognizing and detecting a rotor position signal and transmitting the rotor position signal to a driver through a digital logic signal;

rotor position sensor subassembly (2) including detecting magnetic ring cover (21), detection magnet steel (22) and hall printed circuit assembly (23), detect magnetic ring cover (21) and detect magnet steel (22) and assemble together and form detection magnet steel assembly, it passes through the key or interference connection on the motor output shaft to detect magnet steel assembly, hall printed circuit assembly (23) are installed on the rear end lid, confirm the best mounted position of hall through the debugging.

Further, stator armature (30) includes stator core (301), coreless winding (302) and keysets subassembly (303), coreless winding (302) outside is equipped with stator core (301), the both ends of coreless winding (302) are equipped with keysets subassembly (303).

And a cavity is generated after the stator armature (30) and the locking device (3) are installed, and the cavity is a rotor position sensor assembly (2) installation and debugging space.

Further, the rotor (50) comprises a rotor shaft (501), a magnetic ring (502) and a rotor baffle (503), the magnetic ring (502) is arranged outside the rotor shaft (501), and the rotor baffle (503) is arranged at two ends of the magnetic ring (502).

Further, the magnetic yoke (32) and the armature (34) are made of good magnetic conductors with low coercive force and low remanence, and the support column (31), the winding (33), the brake ring (35), the limiting plate (36) and the spring (37) are made of non-magnetic materials.

Further, the stator core (301) is formed by laminating annular stamped sheets, the coreless winding (302) is wound by a concentric winding, the coreless winding is fixed by shaping, rolling and rounding, and the coreless winding (302) and the stator core (301) are insulated by a layer of high-temperature-resistant aramid paper; pressing into the shell after molding; further performing fixed welding.

Furthermore, the magnetic ring (502) is made of high-temperature-resistant sintered neodymium iron boron or samarium cobalt materials, the HALBACH structure is oriented and magnetized, the surface magnetism and air gap magnetic field curves are standard sinusoidal curves, the rotor magnetic ring is usually 1 pair of poles or multiple pairs of poles, the rotor shaft (501) is made of good magnetic conductive materials, the magnetic ring (502) and the rotor shaft (501) are fixed through high-temperature-resistant glue, and the rotor baffle (503) is pressed at the end part of the magnetic steel and used for axial fixation and dynamic balance of the magnetic steel.

Furthermore, the magnetic opposite poles of the detection magnetic steel (22) corresponding to the detection magnetic steel component correspond to the magnetic opposite poles of the rotor magnetic ring (502) one by one.

Furthermore, the rated rotating speed of the motor is 2000-20000 rpm, and the high-speed rotor can be braked in real time.

The number of preferred motor pole pairs of the motor main body (1) is 2-8, a motor air gap g is between 0.8 mm and 3.5mm, a motor movement air gap g1 is between 0.25 mm and 0.7mm, and the coreless winding (302) is arranged in an annular air gap formed by the stator iron core (301) and the magnetic ring (502).

A manufacturing method of a coreless brushless direct current motor with a locking device is characterized by comprising the following steps:

(1) manufacturing a stator armature: firstly, manufacturing a coreless winding according to requirements, manufacturing by adopting a high-temperature resistant self-adhesive enameled wire, and manufacturing to complete the coreless winding wire cup through coil winding, arrangement, flattening, rounding and finishing; then, a layer of thin high-temperature-resistant aramid paper is pasted on the outer circle of the coreless winding; then pressing the coreless winding wire cup into the annular stator core; further, pressing the stator armature into the housing; further, pressing the wiring board assembly into the shell and welding the wiring board assembly with the hollow cup winding lead; finally, pressing the front end cover into the shell, and fixing the side surface to form a stator armature potting front assembly;

(2) encapsulating the stator armature: the assembly before the stator armature is filled into a prefabricated filling and sealing mold, the assembly before the stator armature is filled is vacuumized, then the prepared high-temperature-resistant epoxy resin is sequentially filled into the assembly before the stator armature is filled and the filling and sealing mold, the assembly is kept stand for 5-10min after the high-temperature-resistant epoxy resin completely penetrates into a gap of the stator armature, natural curing or heating curing is adopted, the stator armature is taken out of the filling and sealing mold after the assembly is finished, and burrs and redundant rubber materials are removed to finish the manufacture of the stator armature;

(3) manufacturing a rotor magnetic ring: the multi-pole magnetic ring is marked according to the magnetic poles, and the inner wall of the multi-pole magnetic ring is coated with high-strength and high-temperature resistant glue and then is loaded into the rotor shaft; then pressing the rotor baffle into the rotor shaft and pressing the magnetic ring tightly; after the glue is solidified, carrying out dynamic balance treatment on the rotor assembly to enable the rotor assembly to reach the dynamic balance magnitude standard of the rotor; performing surface magnetic test on the rotor assembly after the test is finished, and finishing the rotor manufacture after the test is qualified;

(4) assembling a motor main body: pressing the manufactured rotor into a bearing, and putting the manufactured stator armature into the bearing; then pressing the rear end cover into the stator armature assembly, adjusting the axial clearance of the motor to be qualified through the elastic wave pad and the adjusting washer, smoothly rotating the motor, and finally locking and fixing the rear end cover and the stator armature assembly to complete the rotation and the assembly of the motor main body;

(5) debugging, installing and positioning the rotor position sensor assembly: fixing the detection magnetic ring sleeve and the detection magnetic steel according to the identification position; then, connecting the formed detection magnetic steel assembly with a motor rotor shaft through a key, and axially fixing the detection magnetic steel assembly on the end face through a clamping ring; then, the Hall printed circuit assembly (23) is pre-fixed on the rear end cover through an insulating washer and a screw, and the Hoholl induction height is ensured to be H1; finally, wire connection debugging of the wire inlet motor is carried out, the Hall printed circuit assembly (23) is adjusted to the optimal position for motor operation, and the Hall plate assembly is fixed on the motor;

(6) manufacturing a locking device, namely winding a locking device winding, and carrying out wiring and insulating treatment according to requirements to form a ring winding; then pressing the shaped annular winding into a magnetic yoke to form a magnetic yoke armature assembly; then, carrying out vacuum-pumping treatment on the magnetic yoke armature assembly; further, injecting proportioned high-temperature-resistant epoxy resin into the magnetic yoke armature assembly one by one, standing for 5-10min after the resin completely penetrates into the gap of the magnetic yoke armature assembly, and performing natural curing or heating curing to complete the manufacturing of the magnetic yoke armature;

(7) installing and debugging a locking device: on the locking device, a magnetic yoke armature, a support column, a spring and an armature are sequentially arranged on a rear end cover of the motor; then the brake ring (35) is arranged on the motor shaft through a snap ring or a nut; then, electrifying, and setting the pick-up gap of the lock device to be H2; and fixing the limiting plate after the adjustment is in place, completing the installation and debugging of the locking device and completing the manufacturing work of the coreless brushless direct current motor with the locking device.

Due to the adoption of the technical scheme, the method has the following beneficial effects:

the invention relates to an integrated coreless brushless direct current motor with a locking and braking function, which realizes integration of a plurality of functional components of a product and meets the requirement of braking of a high-speed rotor of the coreless motor.

2. By optimizing the sizes of the motor, the rotor position sensor and the locking device and by the multifunctional design of the parts, the size of the motor is fully utilized, the axial and radial sizes of the motor are reduced, and the miniaturization and high power density of the product are realized.

3. The armature winding and the magnetic yoke winding adopt an integral encapsulation process, the winding and a matrix are organically integrated, resin is filled in gaps between the winding and parts, the protection grade and the structural strength of a product are increased, and the environmental resistance is combined, on the other hand, the thermal resistance of the winding to a machine shell is reduced, the heat dissipation performance of the product is improved, the thermal resistance of a motor is reduced, the heat of the winding is led out, the temperature rise of the winding of the motor is reduced, and the power density of the motor is improved;

4. the magnetic field and the magnetic circuit of the motor are optimized, the effective volume and the air gap magnetic density of the motor are improved, and then the magnetic flux in the unit volume of the motor is increased, so that the torque density of the motor is increased, the loss of the motor is reduced, and the efficiency of the motor is improved.

5. The HALBACH structure is adopted to magnetize the integral magnetic ring, the sine of the air gap magnetic density waveform of the motor is good, the sine of the counter electromotive force is good, the waveform distortion rate is low, the motor motion control precision is high, the control operation is smooth, and the vibration and the noise are low.

6. Optimize product structure and mounting means, improve debugging, assembly efficiency and overall structure intensity of product.

Drawings

The invention will be further described with reference to the accompanying drawings in which:

FIG. 1 is a schematic diagram of an external structure of a coreless brushless DC motor with a locking device according to the present invention;

FIG. 2 is a schematic diagram of the internal structure of a coreless brushless DC motor with a locking device according to the present invention;

FIG. 3 is a schematic view of a stator armature according to the present invention;

FIG. 4 is a schematic view of a rotor according to the present invention;

FIG. 5 is a graph showing the magnetic distribution of the rotor surface in the present invention;

FIG. 6 is a schematic view of a rotor position sensor assembly of the present invention;

FIG. 7 is a schematic side view of a coreless brushless DC motor with a locking device according to the present invention;

FIG. 8 is a schematic view of the locking mechanism of the present invention;

fig. 9 is a schematic view of an armature of the present invention;

FIG. 10 is a schematic view of the brake ring of the present invention.

In the figure: 1-a motor body; 2-a rotor position sensor assembly; 3-locking device

10-front end cap; 20-a bearing; 30-a stator armature; 40-a housing; 50-a rotor; 60-rear end cap;

301-a stator core; 302-a coreless winding; 303-a patch panel assembly;

501-rotor shaft; 502-a magnetic ring; 503-rotor baffles;

21 detecting a magnetic ring sleeve; 22-detecting magnetic steel; 23-a hall printed circuit assembly;

31-a support column; 32-a magnetic yoke; 33-a toroidal winding; 34-an armature; 35-a brake ring; 36-a limiting plate; 37-a spring;

g-motor air gap; g 1-motor moving air gap; H1-Hall sensing height; h2-locking device suction gap; h3-armature boss height;

351-brake ring shaft hole boss; 352-brake ring base; 353, braking the retaining shoulder;

341-armature base; 342-stop boss portion.

Detailed Description

In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail below with reference to the accompanying drawings and examples. It should be understood, however, that the description herein of specific embodiments is only intended to illustrate the invention and not to limit the scope of the invention. Moreover, in the following description, descriptions of well-known structures and techniques are omitted so as to not unnecessarily obscure the concepts of the present invention.

As shown in fig. 1 to 10, the coreless brushless dc motor with the locking device comprises a motor main body (1) and the locking device (3), wherein an output end is arranged at the front part of the motor main body (1), and the locking device (3) is arranged at the rear part of the motor main body (1).

The motor main body adopts a hollow cup winding structure mode, the motor main body (1) realizes the output of functional indexes of torque, rotating speed and power, the motor main body consists of a front end cover (10), a bearing (20), a stator armature (30), a machine shell (40), a rotor (50) and a rear end cover (60), the front end of the machine shell (40) is provided with the front end cover (10), the rear end of the machine shell (40) is provided with the rear end cover (10), the middle part of the machine shell (40) is provided with the rotor (50), and the stator armature (30) is arranged outside the rotor (50) in a matching way; the bearings (20) are disposed at both ends of the rotor (50).

The locking device (3) releases the armature after a braking instruction occurs to the motor, and realizes an emergency braking function on the high-speed running rotor, the locking device comprises a brake ring (35), the armature (34) and a magnetic yoke (32), the armature (34) is positioned between the brake ring (35) and the magnetic yoke (32), and the armature (34) moves towards or away from the brake ring (35) to realize braking or unlocking of the motor rotor;

and a suction gap is arranged between the armature (34) and the magnetic yoke (32).

The invention fully considers the optimization of the functions and the structural dimensions of the motor main body, the rotor position sensor and the locking device, adopts multifunctional structural design through transition parts under the condition of meeting the functions and the performance, for example, a rear end cover is not only a bearing and packaging structure of the motor main body, but also a mounting space of the rotor position sensor, and realizes multiple functions of a single part; the space utilization degree of the three modules is fully exerted, and the motor is compact in overall design structure, good in strength and rigidity, large in power density, high in efficiency, complete in function and high in braking rotating speed.

Furthermore, the coreless brushless direct current motor with the locker further comprises a rotor position sensor assembly (2), wherein the rotor position sensor assembly (2) is used for recognizing and detecting a rotor position signal and transmitting the rotor position signal to a driver through a digital logic signal;

rotor position sensor subassembly (2) including detecting magnetic ring cover (21), detection magnet steel (22) and hall printed circuit assembly (23), detect magnetic ring cover (21) and detect magnet steel (22) and assemble together and form detection magnet steel assembly, it passes through the key or interference connection on the motor output shaft to detect magnet steel assembly, hall printed circuit assembly (23) are installed on the rear end lid, confirm the best mounted position of hall through the debugging.

Further, stator armature (30) includes stator core (301), coreless winding (302) and keysets subassembly (303), coreless winding (302) outside is equipped with stator core (301), the both ends of coreless winding (302) are equipped with keysets subassembly (303).

Further, the rotor (50) comprises a rotor shaft (501), a magnetic ring (502) and a rotor baffle (503), the magnetic ring (502) is arranged outside the rotor shaft (501), and the rotor baffle (503) is arranged at two ends of the magnetic ring (502).

Further, a cavity is formed after the stator armature (1) and the locking device (3) are installed, and the cavity is a space for installing and debugging the rotor position sensor assembly (2).

Further, the stator core (301) is formed by laminating annular punching sheets, the hollow cup winding (302) is wound by adopting a concentric winding, and further the hollow cup winding is fixed by shaping, rolling and rounding.

Further, the armature includes an armature base (341) and a stop boss portion (342).

The height of the extension of the braking boss part (342) along the armature base body (341) is H3, the value of H3 is 0.4-1 mm, and the braking boss parts are uniformly distributed along the circumferential direction of the armature base body (341).

Further, the brake ring (35) adopts a T-shaped hollow cylindrical table structure design, the brake ring comprises a brake ring shaft hole boss (351), a brake ring base body (352) and a brake retaining shoulder (353),

the brake block shoulder (353) radially extends out along the outer circle of the brake ring base body (352), and the outer circle of the brake block shoulder (353) is concentric with the outer circle of the brake ring base body (352).

Furthermore, the upper portion of brake ring is equipped with limiting plate (36), the limiting plate pass through screw and support column fixed mounting in on the outer circumference of yoke, the lower part of armature is equipped with the spring.

The motor comprises a motor main body (1), a rotor position sensor assembly (2) and a locking device (3). The motor main body realizes the output of functional indexes such as torque, rotating speed, power and the like, the rotor position sensor assembly realizes the identification and detection of a rotor position signal, the rotor position signal is transmitted to a driver and a locking device through a digital logic signal, the armature is released after a braking instruction occurs to the motor, and the emergency braking function is realized on the rotor which runs at high speed. The armature winding and the locking device winding of the motor are molded and fixed and then are treated in a filling and sealing mode, so that the structural strength, the waterproof property, the insulating strength and the heat dissipation property of the winding are improved, the service life and the reliability of the motor are improved, and the power density of the motor is improved under the same volume.

The functions and the structural dimensions of the motor main body, the rotor position sensor and the locking device are optimized in a full consideration, and under the condition of meeting the functions and the performance, a multifunctional structural design is adopted through transition parts, for example, a rear end cover is a bearing and packaging structure of the motor main body and an installation space of the rotor position sensor, so that multiple functions of a single part are realized; the space utilization degree of the three modules is fully exerted, and the motor is compact in overall design structure, good in strength and rigidity, large in power density, high in efficiency, complete in function and high in braking rotating speed.

A manufacturing method of a coreless brushless direct current motor with a locking device is characterized by comprising the following steps:

(1) manufacturing a stator armature: firstly, manufacturing a coreless winding according to the requirements of a drawing, manufacturing by adopting a high-temperature resistant self-adhesive enameled wire, and manufacturing to complete the coreless winding wire cup through winding, arranging, flattening, rounding and finishing of a coil; then pasting a layer of high-temperature resistant aramid paper with the thickness of 0.05mm on the excircle of the coreless winding; then pressing the coreless winding wire cup into the annular stator core; further, pressing the stator armature into the housing; further, pressing the wiring board assembly into the shell and welding the wiring board assembly with the hollow cup winding lead; and finally, pressing the front end cover into the shell, and screwing down a countersunk head screw on the side surface to fix to form the stator armature potting front assembly.

(2) Encapsulating the stator armature: the assembly before the stator armature is filled into a prefabricated filling and sealing mould, the assembly before the stator armature is filled is vacuumized, then the prepared high-temperature-resistant epoxy resin is sequentially filled into the assembly before the stator armature is filled and the filling and sealing mould, the assembly is kept stand for 5-10min after the high-temperature-resistant epoxy resin completely penetrates into a gap of the stator armature, natural curing or heating curing is adopted, and preferably heating curing is adopted, so that the manufacturing efficiency of a filling and sealing finished product can be improved; and after the manufacturing is finished, the stator armature is taken out of the filling and sealing mold, and burrs and redundant rubber materials are removed to finish the manufacturing of the stator armature.

(3) Manufacturing a rotor magnetic ring: the multi-pole magnetic ring is marked according to the magnetic poles, and the inner wall of the multi-pole magnetic ring is coated with high-strength and high-temperature resistant glue and then is loaded into the rotor shaft; then pressing the rotor baffle into the rotor shaft and pressing the magnetic ring tightly; after the glue is solidified, carrying out dynamic balance treatment on the rotor assembly, wherein the dynamic balance magnitude of the rotor is executed according to the standard of less than or equal to G6.3; and (3) performing surface magnetic test on the rotor assembly, wherein the curve of the multi-pole magnetic ring conforms to the sine shape as much as possible as shown in the attached drawing 5, the drawing 5 is a surface magnetic waveform with the number of pole pairs of 2, if the number of pole pairs P of the motor changes, the surface magnetic waveform is uniformly distributed according to 360/P in a mechanical period, preferably P is between 2 and 8, and the rotor (50) is manufactured after the surface magnetic test is qualified.

(4) Assembling a motor main body: as shown in fig. 2, 3 and 4, the manufactured rotor is pressed well into the bearing and the manufactured stator armature is put into the bearing; then the rear end cover is pressed into the stator armature assembly, the axial clearance of the motor is adjusted to be qualified through the elastic wave pad and the adjusting washer, the motor rotates smoothly, and finally the rear end cover and the stator armature assembly are locked and fixed to complete the rotation and the assembly of the motor body.

(5) Debugging, installing and positioning the rotor position sensor assembly: as shown in fig. 2 and 6, the detection magnetic ring sleeve and the detection magnetic steel are fixed by the viscose glue at the identification position; then, connecting the formed detection magnetic steel assembly with a motor rotor shaft through a key, and axially fixing the detection magnetic steel assembly on the end face through a clamping ring; then, the Hall printed circuit assembly (23) is pre-fixed on the rear end cover through an insulating washer and a screw, so that the Hall sensing height is ensured to be H1, and preferably H1 is 0.8-2.5 mm; and finally, carrying out wiring debugging on the incoming line motor, adjusting the Hall printed circuit assembly (23) to the optimal running position of the motor, and fixing the Hall plate assembly on the motor.

(6) Manufacturing a locking device, namely winding a locking device winding, and carrying out wiring and insulating treatment according to requirements to form a ring winding; then pressing the shaped annular winding into a magnetic yoke to form a magnetic yoke armature assembly; then, carrying out vacuum-pumping treatment on the magnetic yoke armature assembly; and further, sequentially filling the prepared high-temperature-resistant epoxy resin into the magnetic yoke armature assembly, standing for 5-10min after the resin completely penetrates into the gap of the magnetic yoke armature assembly, and performing natural curing or heating curing, preferably heating curing, so that the production efficiency of the filling and sealing finished product can be improved, and the production of the magnetic yoke armature is completed.

(7) Installing and debugging a locking device: on the locking device, a magnetic yoke armature, a support column, a spring and an armature are sequentially arranged on a rear end cover of the motor; then the brake ring (35) is arranged on the motor shaft through a snap ring or a nut; then electrifying, and setting the sucking gap of the lock device to be H2, preferably H2 is between 0.8-2.5 mm; and fixing the limiting plate after the adjustment is in place, completing the installation and debugging of the locking device and completing the manufacturing work of the coreless brushless direct current motor with the locking device.

According to the coreless brushless direct current motor with the locking device, which is disclosed by the embodiment of the invention, is small in axial size, compact in structure, high in braking rotating speed, large in power density and torque density, and can be obtained by adopting the mode; further, the air gap magnetic field of the rotor is optimized, and the HALBACH structure is adopted to orient and magnetize the magnetic ring, so that the air gap magnetic field of the motor approaches to sine, the operation harmonic content of the motor is low, and the counter electromotive force of a winding is sine-shaped. The efficiency of the motor can be effectively improved, the control and running stability of the motor is improved, the torque pulsation is reduced, and the vibration and noise of the motor are reduced. The weak part of the winding is encapsulated by epoxy resin, so that the structural strength, the waterproof property, the insulating strength and the heat dissipation property of the winding are improved, the service life and the reliability of the motor are prolonged, and the power density of the motor is improved under the same volume. The motor adopts the syllogic modular design thinking, and the rotor adopts whole magnetic ring, hall to adopt the disconnect-type installation promptly effectual product reliability that has improved, simplifies motor manufacturing process again, has reduced the manufacturing degree of difficulty, improves production efficiency.

In summary, a coreless brushless dc motor with a locking device is completed, and the preferred embodiments of the present invention are described in detail with reference to the drawings, but the present invention is not limited thereto, and within the scope of the technical idea of the present invention, various simple modifications may be made to the technical solution of the present invention, including any combination of specific technical features, and in order to avoid unnecessary repetition, various possible combinations of the present invention will not be further described. Such simple variations and combinations should be considered within the scope of the present disclosure.

Claims (10)

1. The utility model provides a brushless DC motor of area locking ware coreless, includes motor main part (1) and locking ware (3), the front portion of motor main part (1) is equipped with the output, the rear portion of motor main part (1) is equipped with locking ware (3), its characterized in that:

the motor main body (1) realizes the output of functional indexes of torque, rotating speed and power, and comprises a front end cover (10), a stator armature (30), a machine shell (40), a rotor (50) and a rear end cover (60), wherein the front end of the machine shell (40) is provided with the front end cover (10), the rear end of the machine shell (40) is provided with the rear end cover (10), the middle part of the machine shell (40) is provided with the rotor (50), and the stator armature (30) is arranged outside the rotor (50) in a matching manner;

the locking device (3) releases the armature after a braking instruction occurs to the motor, and realizes an emergency braking function on the high-speed running rotor, the locking device comprises a brake ring (35), the armature (34) and a magnetic yoke (32), the armature (34) is positioned between the brake ring (35) and the magnetic yoke (32), and the armature (34) moves towards or away from the brake ring (35) to realize braking or unlocking of the motor rotor;

and a suction gap is arranged between the armature (34) and the magnetic yoke (32).

2. The coreless, brushless, dc motor with a lock of claim 1, wherein: the device also comprises a rotor position sensor assembly (2), wherein the rotor position sensor assembly (2) realizes the identification and detection of a rotor position signal and transmits the rotor position signal to a driver through a digital logic signal;

rotor position sensor subassembly (2) including detecting magnetic ring cover (21), detection magnet steel (22) and hall printed circuit assembly (23), detect magnetic ring cover (21) and detect magnet steel (22) and assemble together and form detection magnet steel assembly, it passes through the key or interference connection on the motor output shaft to detect magnet steel assembly, hall printed circuit assembly (23) are installed on the rear end lid, confirm the best mounted position of hall through the debugging.

3. The coreless, brushless, dc motor with a lock of claim 1, wherein: the stator armature (30) comprises a stator core (301), a hollow cup winding (302) and a switching plate assembly (303), wherein the stator core (301) is arranged outside the hollow cup winding (302), and the switching plate assembly (303) is arranged at two ends of the hollow cup winding (302);

and a cavity is generated after the stator armature (30) and the locking device (3) are installed, and the cavity is a rotor position sensor assembly (2) installation and debugging space.

4. The coreless, brushless, dc motor with a lock of claim 1, wherein: the rotor (50) comprises a rotor shaft (501), a magnetic ring (502) and a rotor baffle (503), wherein the magnetic ring (502) is arranged outside the rotor shaft (501), and the rotor baffle (503) is arranged at two ends of the magnetic ring (502).

5. The coreless, brushless, dc motor with a lock of claim 3, wherein: the magnetic yoke (32) and the armature (34) are made of good magnetic conductors with low coercive force and low remanence, and the support column (31), the winding (33), the brake ring (35), the limiting plate (36) and the spring (37) are made of non-magnetic materials.

6. The coreless, brushless, dc motor with a lock of claim 3, wherein: the stator core (301) is formed by laminating annular stamped sheets, the hollow cup winding (302) is wound by adopting a concentric winding, the hollow cup winding is further fixed by shaping, rolling and rounding, and the hollow cup winding (302) and the stator core (301) are insulated by adopting a layer of high-temperature-resistant aramid paper; pressing into the shell after molding; further performing fixed welding.

7. The coreless, brushless, dc motor with a lock of claim 1, wherein: the magnetic ring (502) is made of high-temperature-resistant sintered neodymium iron boron or samarium cobalt materials, an HALBACH structure is oriented and magnetized, surface magnetism and air gap magnetic field curves are standard sinusoidal curves, a rotor magnetic ring is usually 1 or more pairs of poles, a rotor shaft (501) is made of good magnetic conduction materials, the magnetic ring (502) and the rotor shaft (501) are fixed through high-temperature-resistant glue, and a rotor baffle (503) is pressed at the end part of magnetic steel and used for axial fixing and dynamic balance of the magnetic steel.

8. The coreless, brushless, dc motor with a lock of claim 4, wherein: and the magnetic opposite poles of the detection magnetic steel (22) corresponding to the detection magnetic steel component correspond to the magnetic opposite poles of the rotor magnetic ring (502) one by one.

9. The coreless, brushless, dc motor with a lock of claim 2, wherein: the rated rotating speed of the motor is 2000-20000 rpm, and the high-speed rotor can be braked in real time;

the number of preferred motor pole pairs of the motor main body (1) is 2-8, a motor air gap g is between 0.8 mm and 3.5mm, a motor movement air gap g1 is between 0.25 mm and 0.7mm, and the coreless winding (302) is arranged in an annular air gap formed by the stator iron core (301) and the magnetic ring (502).

10. A manufacturing method of a coreless brushless direct current motor with a locking device is characterized by comprising the following steps:

(1) manufacturing a stator armature: firstly, manufacturing a coreless winding according to requirements, manufacturing by adopting a high-temperature resistant self-adhesive enameled wire, and manufacturing to complete the coreless winding wire cup through coil winding, arrangement, flattening, rounding and finishing; then, a layer of thin high-temperature-resistant aramid paper is pasted on the outer circle of the coreless winding; then pressing the coreless winding wire cup into the annular stator core; further, pressing the stator armature into the housing; further, pressing the wiring board assembly into the shell and welding the wiring board assembly with the hollow cup winding lead; finally, pressing the front end cover into the shell, and fixing the side surface to form a stator armature potting front assembly;

(2) encapsulating the stator armature: the assembly before the stator armature is filled into a prefabricated filling and sealing mold, the assembly before the stator armature is filled is vacuumized, then the prepared high-temperature-resistant epoxy resin is sequentially filled into the assembly before the stator armature is filled and the filling and sealing mold, the assembly is kept stand for 5-10min after the high-temperature-resistant epoxy resin completely penetrates into a gap of the stator armature, natural curing or heating curing is adopted, the stator armature is taken out of the filling and sealing mold after the assembly is finished, and burrs and redundant rubber materials are removed to finish the manufacture of the stator armature;

(3) manufacturing a rotor magnetic ring: the multi-pole magnetic ring is marked according to the magnetic poles, and the inner wall of the multi-pole magnetic ring is coated with high-strength and high-temperature resistant glue and then is loaded into the rotor shaft; then pressing the rotor baffle into the rotor shaft and pressing the magnetic ring tightly; after the glue is solidified, carrying out dynamic balance treatment on the rotor assembly to enable the rotor assembly to reach the dynamic balance magnitude standard of the rotor; performing surface magnetic test on the rotor assembly after the test is finished, and finishing the rotor manufacture after the test is qualified;

(4) assembling a motor main body: pressing the manufactured rotor into a bearing, and putting the manufactured stator armature into the bearing; then pressing the rear end cover into the stator armature assembly, adjusting the axial clearance of the motor to be qualified through the elastic wave pad and the adjusting washer, smoothly rotating the motor, and finally locking and fixing the rear end cover and the stator armature assembly to complete the rotation and the assembly of the motor main body;

(5) debugging, installing and positioning the rotor position sensor assembly: fixing the detection magnetic ring sleeve and the detection magnetic steel according to the identification position; then, connecting the formed detection magnetic steel assembly with a motor rotor shaft through a key, and axially fixing the detection magnetic steel assembly on the end face through a clamping ring; then, the Hall printed circuit assembly (23) is pre-fixed on the rear end cover through an insulating washer and a screw, and the Hoholl induction height is ensured to be H1; finally, wire connection debugging of the wire inlet motor is carried out, the Hall printed circuit assembly (23) is adjusted to the optimal position for motor operation, and the Hall plate assembly is fixed on the motor;

(6) manufacturing a locking device, namely winding a locking device winding, and carrying out wiring and insulating treatment according to requirements to form a ring winding; then pressing the shaped annular winding into a magnetic yoke to form a magnetic yoke armature assembly; then, carrying out vacuum-pumping treatment on the magnetic yoke armature assembly; further, injecting proportioned high-temperature-resistant epoxy resin into the magnetic yoke armature assembly one by one, standing for 5-10min after the resin completely penetrates into the gap of the magnetic yoke armature assembly, and performing natural curing or heating curing to complete the manufacturing of the magnetic yoke armature;

(7) installing and debugging a locking device: on the locking device, a magnetic yoke armature, a support column, a spring and an armature are sequentially arranged on a rear end cover of the motor; then the brake ring (35) is arranged on the motor shaft through a snap ring or a nut; then, electrifying, and setting the pick-up gap of the lock device to be H2; and fixing the limiting plate after the adjustment is in place, completing the installation and debugging of the locking device and completing the manufacturing work of the coreless brushless direct current motor with the locking device.

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