GB2209437A - Supporting windings in an electric motor - Google Patents

Abstract

A permanent magnet d.c. motor has a frame (10, 11, 12), brush gear (32) supported by the frame, and an armature of disc form supported for rotation. The armature comprises a winding support (19) of electrically insulating material, e.g. plastics material, a plurality of winding coils (22), and commutator (23). The support (19) comprises a hub (20), which defines a base for the commutator, and a plurality of spokes (21) extending radially from the hub. The winding coils are supported between the spokes so that torque developed in the coils is transferred to a motor shaft (18) without distortion of the windings. In another embodiment (Figures 4 to 6, not shown) the winding support comprises a hub and a plurality of bosses angularly spaced apart on an annular base which is integral with the hub, the winding coils being mounted, respectively, about the bosses. <IMAGE>

Description

An electric motor This invention relates to a permanent magnet direct current electric motor and particularly but not exclusively a moving coil disc motor suitable for driving audio equipment.

It is known in instruments and very small p.m.d.c.

motors to make moving coil motors in which the coils are suspended in air in the gap between magnets and return paths. These coils are usually made homogenous by some manner of bonding of the turns of wire. The coils are then lightly attached to a shaft to transmit the torque.

Such arrangements are useful only for very low power systems in which the torque developed by the moving coils will not distort the coils themselves.

For motors with larger torques such an arrangement is not practical.

According to the present invention, there is provided a permanent magnet direct current electric motor, comprising a motor frame, brush gear supported by the motor frame, and an armature of disc form supported for rotation in the motor frame, the armature comprising a winding support, a plurality of winding coils, and a commutator, wherein the winding support comprises a hub mounted on a motor shaft, and means supporting the winding coils against angular movement relative to one another.

Conveniently, said means comprise a plurality of spokes extending radially from the hub and the winding coils are supported between the spokes.

Alternatively, said means may comprise a plurality of bosses angularly spaced apart on an annular base which is integral with the hub, the winding coils being mounted, respectively, about the bosses.

The spokes/bosses serve to lock the winding coils in an angular relationship permitting the torque developed in the winding wire to be transferred to the winding support and from there to a motor shaft without risk of distortion.

Other preferred and/or optional features of the invention are set forth in claims 5 to 9, inclusive.

The invention will now be more particularly described, by way of example, with reference to the accompanying drawings, in which: Figure 1 is a sectional view of one embodiment of an electric motor according to the present invention, the section through the armature being taken along line I-I of Figure 2.

Figure 2 is an underneath plan view of the armature of Figure 1, Figure 3 is a top plan view of the armature of Figure 1, Figure 4 is a sectional view of another embodiment of an electric motor according to the invention, Figure 5 is a top plan view of the armature of Figure 4 with the film bearing the commutator omitted, and Figure 6 is a section taken along line VI-VI of Figure 4, with the electronics components omitted from the printed circuit film.

Referring first to Figures 1 to 3 of the drawings, the motor shown therein has a motor frame comprising a drawn shallow metal can 10 closed by a metal end cap 11.

A plate 12 is provided within the can 10 and forms part of the motor frame. The plate 12 is located axially against a plastics sleeve 13 disposed within the can 10 and the plate 12 is secured in position by dimpling the can from the outside to pinch and thus secure the plate 12 in position.

The inner surface of the base 14 of the can 10 supports four segmental permanent magnets 15. The magnets 15 are glued to the base 14 and adjacent magnets are magnetised in opposite axial directions.

The magnets 15 are stepped at their outer circumferentially extending edges and these stepped edges are engaged by an annular, stepped, radially inwardly extending portion of the sleeve 13 to provide additional support for the magnets. The magnets could be replaced by a single annul us appropriately magnetised.

A radial bearing 16 is fixed in the base 14 of the can 10 and a thrust face 17 is provided on the inside of the plate 12.

A motor armature comprises a shaft 18 which is journalled in the radial bearing 16 and which has a part spherical non-driving end 18a bearing against the thrust face 17. The armature also comprises a plastics winding support 19 mounted fast on the shaft 18. The support 19 comprises a hub 20 and six radially extending spokes 21. Six discrete winding coils 22 are fixed between the spokes 21 of the support 19, such as by glue, and are equi-angularly spaced apart. If desired, the support 19 could also include an integral rim interconnecting the outer ends of the spokes.

With this arrangement utilisation of the air gap in the axial direction can be maximised thereby increasing the useful power output for a given frame size.

The hub 20 of the winding support 19 also defines a base for a commutator, conveniently a face plate commutator 23. The commutator 23 and the connections between the commutator 23 and the winding coils 22 are printed on a film 24 which is secured to the winding support 19, such as by glue. The film 24 is, conveniently, an epoxy resin or polyester based film clad with copper, etched, and subsequently masked in areas to which connections are not made. The commutator comprises six segments 25 arranged in a common plane and if desired these segments may be plated with noble metal. Typically, this would be achieved by plating the copper with nickel and then plating the nickel with noble metal.One end of each winding 22 is connected to a star point provided by conducting track 26 and the other end of each winding 22 is connected to a respective commutator segment 25 by respective conducting tracks 27. Diametrically opposed commutator segments 25 are electrically connected together by respective conducting tracks 28.

A speed regulating circuit 29 provided on a printed circuit film 30 is attached to the outer surface of the plate 12. Electrical terminations of the motor are printed on a tab 31 integral with the film 30 and are led out of the can 10 through an opening in the side wall thereof.

Two resilient precious metal brush leaves 32 forming brush gear of the motor are soldered directly to the printed circuit film 30 and extend through holes 33 in the plate 12. The free end of each brush leaf 32 is forked and these ends of the brush leaves define brushes proper which make contact with the commutator at positions which are spaced apart geometrically by 90 degrees and, as considered electrically, at positions appropriate for optimum commutation. A small elastomeric pad 37 is interposed between each leaf 32 and the film 30 at a position close to the soldered connection to dampen vibration.

In the motor described above each winding coil is open circuited for a period as it passes across a pole face and during this period experiences no change in flux energy. This is particularly advantageous if the flux density across the pole face is substantially trapezoidal, which is likely if high energy magnets, such as neodymium iron boron magnets, are used.

In contrast, if the magnets are of a low energy content then the flux density across the pole faces will be sinusoidal and in that case it may be advantageous to connect the windings to form a parallel pair of delta windings so that each coil plays a continuous part in developing torque.

Coaxial ring magnets 33 and 34 are fitted on the hub 20 and on the radial bearing 16, respectively. The magnets 33 and 34 have their magnetic fields axially oriented with like poles adjacent so that the repulsion forces between the magnets urge the shaft 18 into contact with the thrust face 17.

The end cap 11 is secured to the can 10 by splayed lugs on the end cap 11 engaged in notches in the end of the can 10.

Referring now to Figures 4 to 6, the motor shown therein has a motor frame comprising a drawn shallow metal can 110 closed by a metal cover plate 111.

A mild steel keeper ring 112 is glued to the base 114 of the can 110.

A radial bearing 116 is fixed in the base 114 and a thrust face 117 is provided on the inside of the cover plate 111.

A motor armature comprises a shaft 118 which is journalled in the radial bearing 116 and which has a part spherical non-driving end 118a bearing against the thrust face 117. The armature also comprises a plastics winding support 119 mounted fast on the shaft 118. The support 119 comprises a hub 120, a thin annular base 113 and six triangular, equi-angularly spaced bosses 121 upstanding from the base 113, the hub 120, base 113 and bosses 121 being formed as an integral moulding. Six discrete winding coils 122 are mounted about and fixed to respective bosses 121, such as by glue, to lie in a common plane perpendicular to the axis of the armature.

A film 124, substantially identical to film 24 (Figure 3), has a face plate commutator 123 and connections 127 between the winding coils 122 printed thereon. The film 124, which may be self adhesive, is secured to the upper surface of each boss 121 and to a shoulder 120a provided on the hub 120 of the winding support 119. Connections between the winding coils 122 and the segments of the commutator 123 are the same as described previously in connection with the embodiment shown in Figures 1 to 3.

A speed regulating circuit 129 provided on a printed circuit film 130 is attached to the inner surface of the cover plate 111. Electrical terminations of the motor are printed on a tab 131 integral with the film 130 and are led out of an opening in the side wall thereof or through the cover plate 111.

An annular magnet 115 appropriately magnetised to define a four pole magnetic field is secured to the printed circuit film 130, which may be self adhesive.

Cut outs 115a and 115b are provided in the side of the magnet 115 remote from the film 130 in order to accommodate two resilient precious metal brush leaves 132 which are soldered directly to the printed circuit film 130. The free end of each brush leaf 132 is forked and these ends of the brush leaves define brushes proper which make contact with the commutator at positions which are spaced apart geometrically by 90 degrees and, as considered electrically, at positions appropriate for optimum commutation. A small elastomeric pad may be interposed between each leaf 132 and the magnet 115 at a position close to the soldered connection to dampen vibration.

Coaxial ring magnets 133 and 134 are fitted on the hub 120 and on the radial bearing 116, respectively.

The magnets have their magnetic fields axially oriented with like poles adjacent so that the repulsion forces between the magnets urge the shaft 118 into contact with the thrust face 117.

The above embodiments are given by way of example only and various modifications will be apparent to persons skilled in the art without departing from the scope of the invention defined by the appended claims.

Claims (10)

Claims

1. A permanent magnet direct current electric motor, comprising a motor frame, brush gear supported by the motor frame, and an armature of disc form supported for rotation in the motor frame, the armature comprising a winding support, a plurality of winding coils, and a commutator, wherein the winding support comprises a hub mounted on a motor shaft, and means supporting the winding coils against angular movement relative to one another.

2. An electric motor as claimed in claim 1, wherein said means comprises a plurality of spokes extending radially from the hub and the winding coils are supported between the spokes.

3. An electric motor as claimed in claim 2, wherein there is an equal number of spokes and winding coils.

4. An electric motor as claimed in claim 1, wherein said means comprises a plurality of bosses angularly spaced apart on an annular base which is integral with the hub, the winding coils being mounted, respectively, about the bosses.

5. An electric motor as claimed in any one of the preceding claims, having a four pole magnetic field and six winding coils.

6. An electric motor as claimed in claim 5, wherein each winding is connected at one end to a star point and at the other end to a respective commutator segment, diametrically opposed commutator segments being electrically connected together.

7. An electric motor as claimed in any one of the preceding claims, wherein the hub of the winding support defines a base for the commutator.

8. An electric motor as claimed in any one of the preceding claims, wherein the commutator is a face plate commutator.

9. An electric motor as claimed in any one of the preceding claims, wherein the winding support is of plastics material.

10. An electric motor as claimed in claim 1, substantially as hereinbefore described with reference to the accompanying drawings.