CN111884385A - Hollow cup brushless DC motor - Google Patents
Hollow cup brushless DC motor Download PDFInfo
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- CN111884385A CN111884385A CN202010680848.9A CN202010680848A CN111884385A CN 111884385 A CN111884385 A CN 111884385A CN 202010680848 A CN202010680848 A CN 202010680848A CN 111884385 A CN111884385 A CN 111884385A
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
- H02K3/28—Layout of windings or of connections between windings
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/22—Rotating parts of the magnetic circuit
- H02K1/27—Rotor cores with permanent magnets
- H02K1/2706—Inner rotors
- H02K1/272—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
- H02K1/2726—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of a single magnet or two or more axially juxtaposed single magnets
- H02K1/2733—Annular magnets
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- 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
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/46—Fastening of windings on the stator or rotor structure
- H02K3/50—Fastening of winding heads, equalising connectors, or connections thereto
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- 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
- H02K5/10—Casings or enclosures characterised by the shape, form or construction thereof with arrangements for protection from ingress, e.g. water or fingers
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K5/00—Casings; Enclosures; Supports
- H02K5/24—Casings; Enclosures; Supports specially adapted for suppression or reduction of noise or vibrations
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Brushless Motors (AREA)
Abstract
The invention discloses a coreless brushless direct current motor, which comprises a bearing, a stator, a rotor and a rotor position sensor assembly, wherein a stator coreless winding is a concentric multi-layer winding; the winding lead adopts the adapter plate component to weld the lead; the multipole ring-shaped magnetic pole is P, and the HALBACH structure is adopted to carry out integral multipole magnetization, so that the air gap flux density waveform of the winding coupling part is ensured to be sine; the motor end cover, the shell, the stator, the rotor, the bearing and the Hall positioning circle center are all coaxial; the invention provides the coreless brushless motor which has the advantages of simple product structure, convenient assembly, compact structure, small size, small volume, light weight, small loss, high efficiency, high power and torque density, high back emf sine, low waveform distortion rate, low running noise and vibration, small torque fluctuation, high dynamic response speed, stable control operation, high control precision, high reliability and the like.
Description
Technical Field
The invention relates to the technical field of brushless direct current motors, in particular to a motion executing mechanism.
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 a tooth socket is not arranged on an armature core, and a motor winding is manufactured into a cup type 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.
Along with the expansion of the application range of products such as a model airplane, an unmanned aerial vehicle, a robot, a cradle head and the like, the requirements of light weight, miniaturization, high power density, high torque density, high efficiency, high dynamic response, high reliability, safety and the like are provided for a driving power motor. At present, a hollow cup brushless direct current motor is limited by the process, a 1-pair-pole hexagonal winding structure and a triangular wiring method are mostly adopted, the rotating speed of the motor with the structure is higher, and the back electromotive force and the torque coefficient of the motor are lower, so that the hollow cup brushless direct current motor with high torque density and power density cannot be developed.
Disclosure of Invention
The invention overcomes the defects of the prior art and provides the coreless brushless direct current motor which has the requirements of integration, miniaturization, light weight, high dynamic response and high reliability.
In order to solve the technical problems, the technical scheme of the invention is as follows:
a hollow cup brushless DC motor comprises a bearing, a stator, a rotor and a rotor position sensor assembly, wherein the stator comprises a front end cover, a shell, an annular stator core, a stator hollow cup winding, a support ring and a patch panel assembly; the stator hollow cup winding is a concentric multi-layer winding, and a lead of the stator hollow cup winding is connected with the adapter plate assembly through a welding lead; the rotor comprises a rotor shaft, a multi-pole annular magnetic ring, a detection magnetic steel sheath and detection magnetic steel, wherein the magnetic pole of the multi-pole annular magnetic ring is P, and an HALBACH structure is adopted for integral multi-pole magnetization, so that the air gap flux density waveform of the coupling part of the stator hollow cup winding is sinusoidal; the rotor position sensor assembly comprises a rear end cover, a Hall plate assembly, a screw, an O-shaped sealing ring and a wave spring.
Furthermore, the positioning circle centers of the bearing, the stator, the rotor and the Hall plate assembly are on the same axis; the number of the Hall plates in the Hall plate assembly is 3;
the adapter plate assembly is respectively radially positioned and axially positioned by the casing and the support ring, and a mounting gap of 0.5-1 mm is reserved between the adapter plate assembly and the stator hollow cup winding;
and a tail lead of the stator hollow cup winding is welded on the adapter plate assembly, and a three-phase power line is led out from the adapter plate assembly.
Further, the rear end cover and/or the front end cover are/is provided with a bearing chamber, and an installation groove for placing an O-shaped rubber ring is arranged in the bearing chamber; the O-shaped rubber ring elastically supports the bearing, so that vibration generated in the operation process of the motor is effectively absorbed, and the operation vibration and noise of the motor are reduced;
and a wave spring is arranged between the bearing and the corresponding end cover, so that the bearing pretightening force of the motor is provided and the axial assembly error of the motor is eliminated.
Further, the whole machine shell is cylindrical; the annular stator core is adhered to the inner side of the shell through interference and glue coated on the outer wall of the annular stator core; the hollow cup stator winding is fixed on the inner side of the annular stator core, and insulating paper is arranged between the hollow cup stator winding and the annular stator core for isolation; the coreless stator winding is wound by a self-adhesive enameled wire and is rolled into a cylindrical structure;
manufacturing a stator armature on the shell, the annular stator core and the hollow cup stator winding, pressing the front end cover into the annular shell after the stator armature is assembled in place, then integrally encapsulating the stator, and filling resin into gaps among the hollow cup stator windings and between the hollow cup stator windings and the annular stator core; the casing is made of non-magnetizer stainless steel, and the annular stamped sheet formed by the annular stator core in the casing is formed by laminating more than two silicon steel sheets with the thickness of 0.1-0.5 mm.
Further, the rotor shaft and the multi-pole annular magnetic ring are bonded and fixed through high-temperature-resistant high-strength glue; the number of poles of the multi-pole annular magnetic ring is P, the value of P is between 4 and 12 and is a common multiple of 2; the multi-pole annular magnetic ring is made of high-temperature-resistant and high-performance neodymium iron boron or samarium cobalt; the surface magnetism curve of the multi-pole annular magnetic ring is distributed approximately in a sine wave mode, and the peak value of the surface magnetism is larger than or equal to 3000 gauss;
the rotor shaft is processed by high-strength magnetic-conductive stainless steel;
the number of poles of the multi-pole annular magnetic ring is equal to that of the detection magnetic steel, and the polarities of the multi-pole annular magnetic ring and the detection magnetic steel correspond one to one; the detection magnetic steel is in a circular ring structure formed by splicing a plurality of fan-shaped magnetic steels, the included angle alpha of the fan shape meets the condition that alpha is 360/P, and the orientation plane magnetization is carried out on the magnetic steel orientation of the detection magnetic steel along the axial direction of the fan shape;
after the rotor is assembled, the action is balanced, the balance grade is less than or equal to G6.3, and the stable operation of the rotor under the condition that the rotating speed of the rotor is more than or equal to 10000rpm is met.
Furthermore, the rotor position sensor assembly is sequentially provided with an O-shaped rubber ring, a wave spring and a bearing by taking a rear end cover as a reference, then a Hall plate assembly is fastened by using screws, the Hall plate assembly is formed by flatly attaching three Hall sensors on a PCB, the mechanical included angle between adjacent Hall sensors is theta, theta is 240N/P, N is a positive integer, P is the number of poles of a magnetic ring, and the theta limiting angle is less than or equal to 120 degrees;
the distance H between the bottom surface of the Hall plate assembly of the rotor position sensor assembly and the step of the bearing chamber and the width D of the bearing should satisfy the condition that the H-D value is between 1.5mm and 3 mm.
Furthermore, the rear end cover, the front end cover and the shell are in transition fit, and welding treatment is carried out after the performance of the motor is debugged;
the stator hollow cup winding and the main magnetic loop are coupled to move along with the rotor multi-pole annular magnetic ring in a revolving mode to obtain a waveform with sine higher than counter potential.
Furthermore, in the aspect of the radial space of the motor, the inner diameter of the annular iron core is made large, the size of the magnetic steel is made large in the aspect of the axial space, and through a magnetic field structure, the air gap flux of the motor is improved, the number of effective turns of unit counter potential is reduced, and the resistance and the loss of the motor are further reduced.
Further, the nearest distance between the Hall sensing surface on the rotor position sensor assembly and the detection magnetic steel plane on the rotor is t after the motor is assembled, and the t is 0.5mm to 2 mm.
A coreless brushless DC motor is composed of a motor, a brushless DC motor, a stator, a rotor, a stator.
The invention has the beneficial effects that:
1. the invention realizes compact structure, small size, small volume, light weight, high efficiency, low loss, high power and torque density, high sine of counter potential, low waveform distortion rate, stable control and operation and high precision of the product;
2. by optimizing the magnetic field distribution, the thickness of the iron core yoke, the length of an air gap, the thickness of magnetic steel and the thickness of a rotor yoke are optimized, and the magnetic flux in unit volume is effectively improved, so that the counter electromotive force of unit turns of the motor is improved, the torque coefficient is large, the resistance under the unit torque coefficient is further reduced, the copper loss of the motor is reduced, and the efficiency, the torque density and the power density of the motor are effectively improved.
3. By optimizing the air gap magnetic field, the counter electromotive force of the motor has high sine degree, low waveform distortion rate, stable operation of the motor, low noise and vibration, small torque fluctuation, stable control operation and high precision.
4. The concentric winding is adopted for winding and layout, the winding wires are not overlapped, the air gap is short under the effective turns, and the multilayer winding layout can be realized under the limited annular air gap, so that the space utilization rate of the winding is improved, the resistance is low under the unit back electromotive force, the copper loss of the motor is small, the copper loss of the motor is reduced, and the efficiency, the torque density and the power density of the motor are effectively improved;
5. by optimizing the air gap magnetic field, adopting an integral multi-pole magnetizing magnetic ring with an HALBACH structure and reasonably distributing key parameters such as the number of poles of the magnetic ring, the length of an air gap, the thickness of a stator magnet yoke and the like, the motor has good air gap magnetic density waveform sine property, good back electromotive force sine property, low waveform distortion rate, high back electromotive force sine degree of the motor, low waveform distortion rate, stable motor operation, low noise and vibration, small torque fluctuation, stable control operation and high precision;
6. the design of integral multi-pole annular magnetic steel is adopted, the rotor matching process is simplified, the production and manufacturing difficulty is reduced, and the axial size of the motor is effectively shortened by directly tracking the magnetic steel and the end tracking magnetic steel, so that the motor is more compact and the rigidity of the rotor is good.
Drawings
FIG. 1 is a cross-sectional view of the structure of the present invention;
FIG. 2 is a cross-sectional view of a stator construction of the present invention;
FIG. 3 is a cross-sectional view of a rotor structure of the present invention;
FIG. 4 is a surface magnetic curve graph of the multi-pole annular magnetic ring of the present invention;
FIG. 5 is a cross-sectional structural view of the rotor position sensor assembly of the present invention;
FIG. 6 is a schematic diagram of a Hall plate assembly of the present invention.
Reference numbers in the figures:
the device comprises a bearing 1, a stator 2, a rotor 3 and a rotor position sensor assembly 4;
the stator core assembly comprises a front end cover 21, a machine shell 22, an annular stator core 23, a stator hollow cup winding 24, a support ring 25 and an adapter plate assembly 26; the rotor comprises a rotor shaft 31, a multi-pole annular magnetic ring 32, a detection magnetic steel sheath 33 and detection magnetic steel 34; the rear end cover 41, the Hall plate assembly 42, a screw 43, an O-shaped sealing ring 44 and a wave spring 45; t Hall sensing distance, D bearing thickness, and distance from the H end cover bearing chamber step to the bottom surface of the PCB of the Hall plate assembly.
Detailed Description
The invention is further described with reference to the following figures and specific examples. It should be noted that the examples are only for specifically illustrating the present invention, and the purpose thereof is to make the technical solution of the present invention better understood by those skilled in the art, and should not be construed as limiting the present invention. The structures not described in detail are all processed in a conventional configuration.
In addition, the embodiments and the features of the embodiments in the present invention may be combined with each other without conflict. In the description of the present invention, references to "center", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", and the like indicate orientations or positional relationships based on those shown in the drawings, and are only for convenience of description and simplicity of description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed in a specific orientation, and be operated, and thus, are not to be construed as limiting the present invention.
The existing coreless brushless motor is limited by the process, 1 pair of poles is adopted, a hexagonal winding structure and a triangular wiring method are adopted, and the motor yoke part is thicker and the outer diameter of a rotor is smaller in general structure according to the analysis of a magnetic circuit structure, and the brushless motor is started by combining the following brushless direct current motor formula:
from the formula analysis, at the motor length LaSpeed n, pole arc coefficient alphaiCoefficient of winding kωMagnetic field intensity A and air gap average motor BUnder the same heat dissipation condition, the output power P' of the motor is proportional to the outer diameter D of the armature or the rotora 2. At present, 1 pair of poles are under the same peripheral size of a motor, the yoke part of the stator is large, the effective size Da of the motor is small, the overall magnetic flux of the motor is low, the torque and power output of the coreless brushless direct current motor are further influenced, the efficiency of the motor is improved, and the volume of the motor is required to be increased if the output of the same torque density is achieved. Therefore, as indexes such as power density, torque density and miniaturization are gradually improved, under the condition of specific outer diameter and thickness of the motor, the magnetic circuit characteristics are required to be sufficient, air gap flux density and effective rotor diameter are considered, and effective working flux of the motor is improved. The specific implementation mode of the scheme is as follows:
as shown in fig. 1, a coreless brushless dc motor includes a bearing 1, a stator 2, a rotor 3, and a rotor position sensor assembly 4. The positioning circle centers of the bearing 1, the stator 2, the rotor 3 and the Hall plate assembly 42 are on the same axis.
As shown in fig. 2, the stator 2 includes a front cover 21, a casing 22, an annular stator core 23, a stator hollow cup winding 24, a support ring 25, and an adapter plate assembly 26. The stator hollow cup winding 24 is a concentric multi-layer winding, and the lead of the stator hollow cup winding 24 is connected with the adapter plate assembly 26 through a welding lead.
Wherein, the rear end cover 41 of the rotor position sensor component 4 and/or the front end cover 21 of the stator 2 are provided with bearing chambers, and mounting grooves for placing O-shaped rubber rings 44 are arranged in the bearing chambers; the O-shaped rubber ring 44 elastically supports the bearing 1, effectively absorbs vibration generated in the operation process of the motor and reduces the operation vibration and noise of the motor. A wave spring 45 is further arranged between the bearing 1 and the corresponding end cover, and the wave spring 45 provides pre-tightening force for the bearing 1 of the motor and eliminates axial assembly errors of the motor.
The casing 22 is cylindrical as a whole; the annular stator iron core 23 is adhered to the inner side of the casing 22 through interference and glue smeared on the outer wall; the hollow cup stator winding 24 is fixed on the inner side of the annular stator core 23, and insulating paper is arranged between the hollow cup stator winding 24 and the annular stator core 23 for isolation; the coreless stator winding 24 is wound by a self-adhesive enameled wire and is rolled into a cylindrical structure. The adapter plate assembly 26 is respectively positioned radially and axially by the casing 22 and the support ring 25, and a mounting gap of 0.5-1 mm is reserved between the adapter plate assembly 26 and the stator hollow cup winding 24. The tail lead of the stator hollow cup winding 24 is welded on the adapter plate assembly 26, and a three-phase power line is led out from the adapter plate assembly 26.
The stator armature is manufactured on the machine shell 22, the annular stator core 23 and the hollow cup stator winding 24, after the stator armature is assembled in place, the front end cover 21 is pressed into the annular machine shell 22, then the stator 2 is integrally encapsulated, resin is filled in installation gaps among the hollow cup stator windings 24 and the annular stator core 23, and the strength and the heat dissipation effect of the whole stator 2 are improved. The casing 22 is made of a non-magnetizer stainless steel material, and the annular stamped sheet formed by the annular stator core 23 in the casing 22 is formed by laminating at least more than two silicon steel sheets with the thickness of 0.1-0.5 mm.
As shown in fig. 3, the rotor includes a rotor shaft 31, a multi-pole annular magnetic ring 32, a detection magnetic steel sheath 33, and a detection magnetic steel 34. As shown in fig. 4, the magnetic pole of the multi-pole annular magnetic ring 32 is P, and the HALBACH structure is adopted to perform integral multi-pole magnetization, so that the air gap flux density waveform of the coupling part of the stator coreless winding 24 is sinusoidal, and the effect that the sine degree is higher than the back electromotive force waveform can be obtained as the stator coreless winding 24 is coupled with the main magnetic loop and rotates with the rotor multi-pole annular magnetic ring 32.
The rotor shaft 31 is machined from high strength magnetically conductive stainless steel. The rotor shaft 31 and the multi-pole annular magnetic ring 32 are bonded and fixed through high-temperature-resistant high-strength glue. The number of poles of the multi-pole annular magnetic ring 32 is P, and the value of P is 4 to 12 and is a common multiple of 2. The multi-pole annular magnetic ring 32 is made of high-temperature-resistant and high-performance neodymium iron boron or samarium cobalt; the surface magnetism curve of the multi-pole annular magnetic ring 32 is distributed approximately in a sine wave mode, and the peak value of the surface magnetism is larger than or equal to 3000 gauss. The number of poles of the multi-pole annular magnetic ring 32 is equal to that of the detection magnetic steel 34, and the polarities correspond to one another; the detection magnetic steel 34 is of a circular ring structure formed by splicing a plurality of fan-shaped magnetic steels, the included angle alpha of the fan shape meets the requirement that alpha is 360/P, and the magnetic steel orientation of the detection magnetic steel 34 is magnetized along the axial direction of the fan shape. After the rotor is assembled, the action is balanced, the balance grade is less than or equal to G6.3, and the stable operation of the rotor under the condition that the rotating speed of the rotor is more than or equal to 10000rpm is met.
As shown in fig. 5 and 6, the rotor position sensor assembly 4 includes a rear end cover 41, a hall plate assembly 42, a screw 43, an O-ring 44, and a wave spring 45. The number of the Hall plates in the Hall plate assembly 42 is 3.
The rotor position sensor assembly 4 is sequentially provided with an O-shaped rubber ring 44, a wave spring 45 and a bearing 1 by taking a rear end cover 41 as a reference, then a Hall plate assembly 42 is fastened by a screw 43, the Hall plate assembly 42 is formed by flatly attaching three Hall sensors on a PCB, the mechanical included angle between adjacent Hall sensors is theta, theta is 240N/P, N is a positive integer, P is the number of poles of a magnetic ring, and the theta limiting angle is smaller than or equal to 120 degrees. The distance H between the bottom surface of the Hall plate assembly 42 of the rotor position sensor assembly 4 and the step of the bearing chamber and the width D of the bearing should satisfy the condition that the H-D value is between 1.5mm and 3 mm.
Preferably, the rear end cover 41, the front end cover 21 and the casing 22 are in transition fit, the overall performance of the motor is tested according to the functions and performance requirements of the coreless brushless direct current motor, and after all indexes meet the design requirements, the motor end cover and the casing are welded, so that the coreless brushless direct current motor is manufactured. After the motor is assembled, the nearest distance between the Hall sensing surface on the rotor position sensor assembly 4 and the plane of the detection magnetic steel 34 on the rotor 3 is t, and the t is 0.5mm to 2 mm. In the radial space of the motor, the inner diameter of the annular stator core 23 can be sufficiently increased while ensuring the strength. The layout in the axial space aspect takes the structural characteristics of the parts into consideration, the size in the range of the distance between the two bearings is fully utilized, and the size of the magnetic steel is enlarged as much as possible. Through the layout, the magnetic field structure is optimized, the air gap flux of the motor is improved, the effective turns of unit counter potential is reduced, the resistance and the loss of the motor are further reduced, and the efficiency, the torque and the power density of the motor are improved.
In conclusion, the magnetic field of the motor is optimized, the air gap flux under the unit volume is improved as much as possible, 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 harmonic content of the motor is low, and the counter potential of the winding is sine-shaped. The motor loss can be effectively reduced, the motor efficiency, the torque density, the power density and the like are improved, the motor control and running stability is improved, the torque pulsation is reduced, and the motor vibration and noise 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 hollow cup brushless direct current motor has the advantages of simplified structure, convenient assembly, compact structure, small size, small volume, light weight, small loss, high efficiency, high power and torque density, high back electromotive force sine, low waveform distortion rate, low running noise and vibration, small torque fluctuation, high dynamic response speed, stable control operation, high control precision, high reliability and the like.
The preferred embodiments of the present solution are described in detail above with reference to the accompanying drawings, but the present solution is not limited thereto. Within the scope of the technical idea of the solution, many simple variants can be made to the solution of the solution, including combinations of the individual specific technical features in any suitable way. In order to avoid unnecessary repetition, the present solution does not further describe various possible combinations. These simple variations and combinations should also be considered as disclosed in the present solution, all falling within the scope of protection of the present solution.
Claims (10)
1. The utility model provides a coreless brushless DC motor, includes bearing (1), stator (2), rotor (3) and rotor position sensor subassembly (4), its characterized in that: the stator (2) comprises a front end cover (21), a shell (22), an annular stator iron core (23), a stator hollow cup winding (24), a support ring (25) and an adapter plate assembly (26); the stator hollow cup winding (24) is a concentric multi-layer winding, and a lead of the stator hollow cup winding (24) is connected with the adapter plate component (26) through a welding lead; the rotor comprises a rotor shaft (31), a multi-pole annular magnetic ring (32), a detection magnetic steel sheath (33) and detection magnetic steel (34), wherein the magnetic pole of the multi-pole annular magnetic ring (32) is P, an HALBACH structure is adopted for integral multi-pole magnetization, and the air gap magnetic density waveform of the coupling part of the stator hollow cup winding (24) is sine; the rotor position sensor assembly (4) comprises a rear end cover (41), a Hall plate assembly (42), a screw (43), an O-shaped sealing ring (44) and a wave spring (45).
2. A coreless, brushless, dc motor according to claim 1, wherein: the positioning circle centers of the bearing (1), the stator (2), the rotor (3) and the Hall plate assembly (42) are on the same axial lead; the number of the Hall plates in the Hall plate assembly (42) is 3;
the adapter plate assembly (26) is respectively positioned radially and axially by the casing (22) and the support ring (25), and a mounting gap of 0.5-1 mm is reserved between the adapter plate assembly (26) and the stator hollow cup winding (24);
and a tail lead of the stator hollow cup winding (24) is welded on the adapter plate component (26), and a three-phase power line is led out from the adapter plate component (26).
3. A coreless, brushless, dc motor according to claim 1, wherein: the rear end cover (41) and/or the front end cover (21) are/is provided with a bearing chamber, and an installation groove for placing an O-shaped rubber ring (44) is arranged in the bearing chamber; the O-shaped rubber ring (44) elastically supports the bearing (1), so that vibration generated in the operation process of the motor is effectively absorbed, and the operation vibration and noise of the motor are reduced;
a wave spring is arranged between the bearing (1) and the corresponding end cover, so that the bearing (1) pretightening force of the motor is provided and the axial assembly error of the motor is eliminated.
4. A coreless, brushless, dc motor according to claim 1, wherein: the shell (22) is integrally cylindrical; the annular stator iron core (23) is adhered to the inner side of the shell (22) through interference and glue smeared on the outer wall of the annular stator iron core; the coreless stator winding (24) is fixed on the inner side of the annular stator core (23), and insulating paper is arranged between the coreless stator winding (24) and the annular stator core (23) for isolation; the coreless stator winding (24) is wound by a self-adhesive enameled wire and is rolled into a cylindrical structure;
manufacturing stator armatures on a machine shell (22), an annular stator core (23) and a hollow cup stator winding (24), pressing a front end cover (21) into the annular machine shell (22) after the stator armatures are assembled in place, then integrally encapsulating a stator (2), and filling resin into gaps among the hollow cup stator windings (24) and between the hollow cup stator windings (24) and the annular stator core (23); the casing (22) is made of non-magnetizer stainless steel, and the annular stamped sheet formed by the annular stator core (23) in the casing (22) is formed by laminating at least more than two silicon steel sheets with the thickness of 0.1-0.5 mm.
5. A coreless, brushless, dc motor according to claim 1, wherein: the rotor shaft (31) and the multi-pole annular magnetic ring (32) are bonded and fixed through high-temperature-resistant high-strength glue; the number of poles of the multi-pole annular magnetic ring (32) is P, the value of P is between 4 and 12 and is a common multiple of 2; the multi-pole annular magnetic ring (32) is made of high-temperature-resistant and high-performance neodymium iron boron or samarium cobalt; the surface magnetism curve of the multi-pole annular magnetic ring (32) is distributed approximately in a sine wave mode, and the peak value of the surface magnetism is larger than or equal to 3000 gauss;
the rotor shaft (31) is processed by high-strength magnetic-conductive stainless steel;
the number of poles of the multi-pole annular magnetic ring (32) is equal to that of the detection magnetic steel (34), and the polarities of the multi-pole annular magnetic ring and the detection magnetic steel correspond one to one; the detection magnetic steel (34) is of a circular ring structure formed by splicing a plurality of fan-shaped magnetic steels, the included angle alpha of the fan shape meets the condition that alpha is 360/P, and the magnetic steel orientation of the detection magnetic steel (34) is magnetized along the axial direction of the fan shape in an orientation plane;
after the rotor is assembled, the action is balanced, the balance grade is less than or equal to G6.3, and the stable operation of the rotor under the condition that the rotating speed of the rotor is more than or equal to 10000rpm is met.
6. A coreless, brushless, dc motor according to claim 1, wherein: the rotor position sensor assembly (4) is characterized in that an O-shaped rubber ring (44), a wave spring (45) and a bearing (1) are sequentially arranged in a rear end cover (41) serving as a reference, then a Hall plate assembly (42) is fastened by a screw (43), the Hall plate assembly (42) is formed by flatly attaching three Hall sensors to a PCB, the mechanical included angle between adjacent Hall sensors is theta, theta is 240N/P, N is a positive integer, P is the number of poles of a magnetic ring, and theta is limited by an angle smaller than or equal to 120 degrees;
the distance H between the bottom surface of a Hall plate assembly (42) of the rotor position sensor assembly (4) and the step of the bearing chamber and the width D of the bearing should satisfy the condition that the H-D value is between 1.5mm and 3 mm.
7. A coreless, brushless, dc motor according to claim 1, wherein: the rear end cover (41), the front end cover (21) and the shell (22) are in transition fit, and welding treatment is carried out after the performance of the motor is debugged;
the stator hollow cup winding (24) is coupled with a main magnetic loop and rotates along with the rotor multi-pole annular magnetic ring (32) to obtain a waveform with sine higher than counter potential.
8. A coreless, brushless, dc motor according to claim 1, wherein: in the aspect of radial space of the motor, the inner diameter of the annular iron core is made large, the size of the magnetic steel is made large in the aspect of axial space, and through a magnetic field structure, the air gap flux of the motor is improved, the number of effective turns of unit counter potential is reduced, and the resistance and the loss of the motor are further reduced.
9. A coreless, brushless, dc motor according to claim 1, wherein: after the motor is assembled, the nearest distance between the Hall sensing surface on the rotor position sensor assembly (4) and the plane of the detection magnetic steel (34) on the rotor (3) is t, and the t is between 0.5mm and 2 mm.
10. A coreless brushless dc motor, characterized in that said motor is a coreless brushless dc motor according to any of claims 1 to 9.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202010680848.9A CN111884385A (en) | 2020-07-15 | 2020-07-15 | Hollow cup brushless DC motor |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202010680848.9A CN111884385A (en) | 2020-07-15 | 2020-07-15 | Hollow cup brushless DC motor |
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| CN111884385A true CN111884385A (en) | 2020-11-03 |
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Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN112737175A (en) * | 2020-12-30 | 2021-04-30 | 姜堰经济开发区科创中心 | Compact type slotless permanent magnet spindle motor |
| CN112821685A (en) * | 2021-02-23 | 2021-05-18 | 江西江特电机有限公司 | Design method for saving axial space of motor |
| CN114301195A (en) * | 2021-12-30 | 2022-04-08 | 贵阳万江航空机电有限公司 | Brushless motor stator, brushless motor stator fixing method and brushless motor |
| CN114337388A (en) * | 2021-12-24 | 2022-04-12 | 广东麦珂威尔健康科技有限公司 | Dual-motor fitness equipment driving device based on linear Hall and control method thereof |
| CN114884256A (en) * | 2022-07-07 | 2022-08-09 | 常州市昊升电机股份有限公司 | Brushless coreless motor convenient to assembly |
| CN115566821A (en) * | 2022-11-23 | 2023-01-03 | 秦皇岛达则机电设备有限公司 | Polynomial magnetic steel stator structure and magnetic shaft type linear motor |
| CN116365757A (en) * | 2023-06-01 | 2023-06-30 | 苏州心岭迈德医疗科技有限公司 | Hollow cup motor |
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Cited By (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112737175A (en) * | 2020-12-30 | 2021-04-30 | 姜堰经济开发区科创中心 | Compact type slotless permanent magnet spindle motor |
| CN112821685A (en) * | 2021-02-23 | 2021-05-18 | 江西江特电机有限公司 | Design method for saving axial space of motor |
| CN114337388A (en) * | 2021-12-24 | 2022-04-12 | 广东麦珂威尔健康科技有限公司 | Dual-motor fitness equipment driving device based on linear Hall and control method thereof |
| CN114301195A (en) * | 2021-12-30 | 2022-04-08 | 贵阳万江航空机电有限公司 | Brushless motor stator, brushless motor stator fixing method and brushless motor |
| CN114884256A (en) * | 2022-07-07 | 2022-08-09 | 常州市昊升电机股份有限公司 | Brushless coreless motor convenient to assembly |
| CN114884256B (en) * | 2022-07-07 | 2022-09-09 | 常州市昊升电机股份有限公司 | Brushless coreless motor convenient to assembly |
| CN115566821A (en) * | 2022-11-23 | 2023-01-03 | 秦皇岛达则机电设备有限公司 | Polynomial magnetic steel stator structure and magnetic shaft type linear motor |
| CN116365757A (en) * | 2023-06-01 | 2023-06-30 | 苏州心岭迈德医疗科技有限公司 | Hollow cup motor |
| CN116365757B (en) * | 2023-06-01 | 2023-08-08 | 苏州心岭迈德医疗科技有限公司 | Hollow cup motor |
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