JPH05505299A - Improvement of slotless, brushless and large air gap motors - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed description of the invention] Slotless, brushless, large air gear, and improved motors with brushes Naoto upper uni Satooka mutual TECHNICAL FIELD The present invention relates generally to electromechanical devices such as electric motors and generators, and in particular to slot It relates to electric motors that are brushless and have a large air supply.

Well, once! Emperor Slotless, brushless, large air gap electric motors are well known and widely used. It is used for various purposes. These applications include power equipment, consumer appliances, and and the automobile industry, but these are just a few examples.

The nature of this type of electric motor allows it to produce the desired torque and horsepower for different applications. To obtain this, the motor must be substantially redesigned. In addition, it is usually Different electronic packages are required to control different motors. this Due to these factors and the difficulty of manufacturing slotless, branless motors, Motors can be used for many parts in which motors are used or for which it is desired to use motors. It now occupies the major cost for parts. For example, the power machine mentioned above In a vessel or utensil. Therefore, in these and other instruments and applications, If the cost of data can be reduced, the impact on the total cost of the finished part will be significant. Become. Moreover, such motors are used in large quantities in large quantities, for example in the automobile industry. When used, the cost of one or several motors can be reduced to one item, i.e. Although it is unlikely to have a significant impact on the cost of the vehicle, as a result of mass production the overall Motor costs are significant and any reduction in that cost would be beneficial.

Mero 1 tres, branless motors with large air gear knobs are relatively efficient. not good. The reasons for the better efficiency include other losses such as typical heat dissipation. Similarly, hysteresis losses and eddy current losses can be mentioned. Other sources that are less efficient An example of this is when the input electrical energy is of only one type, i.e. or limited to AC power sources). Such mode By improving the efficiency of the motor and making it compatible with both types of II sources, motors are generally becoming more readily available, and the market for such motors is expanding. It will be big. For example, the use of such motors in tools such as manual drills is desired. This allows it to operate with less heat than traditional manual drills. It can be plugged into a wall outlet or can also be powered.

Judame 11 The present invention is an improvement to a slotless, brushless motor with a large air gear knob. Regarding. Such improvements are related to efficiency of operation, ease of manufacture and versatility. Ru. The present invention provides the rectifier of the present invention regardless of the rectifier structure and the torque and horsepower characteristics. m for controlling a number of (preferably all) motors designed according to the structure. Concerning versatile electronic control/<, 7 cages.

SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide a highly efficient slotless, branless and large air gap. The objective is to provide a motor with high power consumption.

Another object of the invention is to automate manufacturing and create unique coil winding configurations. By adopting this method, the manufacturing cost of such motors can be simplified and reduced. be.

Another objective is to minimize the number of coil turns required to drive the motor. be.

Another objective is that the control electronics have a common cell, l-, for any size motor. Provides a rectifier circuit that allows the control electronics to be used in the motor. It should be an integrated part of the assembly.

Yet another object is to provide a variable speed motor, the speed of which is is determined by modulating the pulse width of the applied power.

According to one aspect of the invention, a slotless, brushless, large air gap A certain electric motor has a stator having a field winding and a field iron, A large number of consecutively staggered windings such that the field windings are approximately flat windings. A stator that makes polygonal turns and is placed inside the stator. A rotor having a shaft and a permanent magnet mounted thereon.

The polygonal shape can be, for example, rectangular or hexagonal in shape.

According to other aspects, a method of creating a field winding for an electric motor has a polygonal shape. spirally winding the wire around the shaped mold and winding the wire at a predetermined distance; the step of leaving a space with no space, the space being a predetermined distance Steps with a length and the wire windings are approximately flattened to form approximately a polygonal shape. Fill the unwound space with successively staggered turns of windings with In order to form a hollow cylinder, the steps of crushing the two sides of the mold are as follows: winding the flattened winding.

According to yet another aspect of the invention, the electric motor includes a field winding and a field bank iron. A stator having a field winding having a Y-shape, the field winding having a Y-shape, A rectifier switch is installed between each end and ground, and the common connection point of the Y is connected to the power source. a stator having a power switch between the source and the shaft located within that stator; a rotor with a permanent magnet mounted thereon; and a rotor that controls the switch. It is equipped with an integrated circuit.

Further, according to other aspects, the electric motor has a field winding and a field back iron. a stator disposed within the stator, a shaft, and a permanent mounted thereon; permanent magnet, and a permanent magnet to complete the magnetic circuit between the mutually opposing poles of the permanent magnet. and a rotor having a pair of elements placed on either side of the magnet.

According to another aspect of the invention, a polyphase motor includes a field winding and a field back iron. A stator having a field winding arranged in a Y shape, each of which has a field winding arranged in a Y shape. A rectifier switch is provided between the end of the Y and the ground, and the common connection point of the Y is connected to the power supply. a stator having a power switch between; a shaft and a stator disposed within the stator; and a rotor having permanent magnets mounted thereon.

Further, according to other aspects, the electric motor has a field winding and a field back iron. a stator whose field windings are activated by both rectified alternating current and direct current. sections for activation and sections activated only by rectified alternating current. a stator with a shaft located within the stator and mounted on it; and a rotor having permanent magnets.

According to yet another aspect of the invention, a method of commutating a polyphase motor includes: providing power to the line phase and interrupting power to the first field winding phase; a step of dissipating the retained energy of the first winding phase into a second winding phase; and applying power to the second winding phase.

These and other objects, advantages, features and aspects of the present invention will be explained in detail below. It will become clear in the light.

To achieve the foregoing and related objects, the present invention provides the following features in the specification: It has the features specifically described and specified in the claims. The explanation below The accompanying drawings set forth in detail certain illustrative embodiments of the invention.

However, this is not a major part of the invention or the variety that can be used. This is just one possible method.

that the scope of the invention should be determined by the claims and their equivalents; Of course.

1 standing i! f anti-plate In the attached drawings, Figure 1 shows the slotless, branless, large air gear knob motor of the present invention. This is an illustration.

FIG. 2 is an end view of the motor showing the blocked portion when viewed in the direction of arrow 2-2 in FIG. be.

FIG. 3 is a top view of the electronic package of the present invention.

FIG. 4 is a cross-sectional view of the motor as viewed in the direction of arrow 4-4 in FIG.

FIG. 5 illustrates the magnetic field at both ends of a typical permanent magnet rotor.

FIG. 6 illustrates the magnetic field at both ends of the rotor using the magnetically permeable element of the present invention. It is.

FIG. 7 is a perspective view of the coil winding of the present invention being wound around a mold.

FIG. 8 is a diagram in which coil phase windings, which are an example of the present invention, are wired in series.

FIG. 9 is a diagram in which the coil phase windings are wired in parallel.

FIG. 10 is a plan view of the fill winding showing the phase configuration.

FIG. 11 is a diagram in which the coil winding is incompletely collapsed.

FIG. 12 is a diagram of a coil winding about to be wound around a cylindrical core.

FIG. 13 is a cross-sectional view of one segment of each phase of the coil winding.

FIG. 14 is a cross-sectional view of the completed coil winding and permanent magnet stator.

Figure 15 shows a hexagonal winding die for use in the motor of Figure 1. 3 is a diagram illustrating another embodiment of the coil.

FIG. 16 is a schematic electrical diagram of the motor and control circuit components of the present invention.

FIG. 17 is a schematic diagram of the rectifier section of the circuit of FIG. 16.

FIG. 18 shows the coil section and FIG.

FIG. 19 is a diagram showing a pulse width modulation structure of the present invention.

FIG. 20 shows an arrangement of other embodiments of the invention suitable for use with DC or AC power. FIG. 2 is a schematic diagram of an electrical circuit showing the flow structure and ii source.

Two meters of good plates! negation Refer to the drawings in which like parts have been given the same reference numerals.

First, Figures 1 to 4 show the slotless, planless and large air gap of the present invention. An electric motor 10 is shown with a pull-up. The motor 10 is a conventional slotless, brushless motor. Similar to the Siles motor, a permanent magnet rotor assembly 12 and a wound stator 14 It is equipped with The rotor assembly I2 is surrounded by a back iron core 18. , and an extension shaft 16 surrounded by permanent magnets 20 in turn. stator assembly The iron 14 includes a coil winding 22 and a field back iron 24 surrounding the coil winding. The coil winding has sufficient space to accommodate the rotor. It has an inner diameter to accommodate Between the permanent magnet 20 and the inner diameter of the field back iron 24 The space partially occupied by the coil winding 22 is the air gap. 25.

The motor 10 has an open end section 28, an intermediate section 3-0, and a closed end section. A housing assembly knob 926 is further provided having a housing adjustment knob 926. housing The assembly 26 includes the rotor assembly 12 and the stator assembly ]4, respectively. It is for storage. Stator assembly 14 is connected to housing assembly 26 ζ is fixed, while the rotor assembly] 2 can rotate around the long axis Z. It is attached to the sea urchin.

The rotor assembly 12 includes an open end housing assembly 28 and a closed end housing. A pair of bearings 34a and 34b installed in the bearing 32 and is radially and axially secured within housing assembly 26.

As a result, rotor assembly IJ12 rotates freely within stator assembly 14. . The rotor shaft 16 is attached to a load and rotates the load relative to it. It extends through open-ended housing section 28 to accommodate the needs of the user.

A thermally conductive end member 38 in contact with the closed end housing assembly 32 1o to seal the motor from contamination. The end member 38 has an electric A number of terminals 41 and 42 are provided which are connected to a power source and a motor control input, respectively. (FIG. 2), a printed circuit board 44 is mounted inside the end member 38. and is electrically connected to terminals 41 and 42 (Figs. 1 and 3), and is fitted with the control electronics of motor 1o (indicated generally by 46). .

Circuit board 44 is preferably comprised of a thin Kapton substrate; Circuit buses and mounting pads are printed thereon in a known manner. integrated circuit, transformer Control electronic circuit elements such as resistors and pole effect sensors are The circuit board 44 is electrically and mechanically connected to the circuit board 44 by connecting or similar techniques. control Electromagnetic interference (EMI) systems are used to reduce the negative effects of electrical noise on electronic components. A field 47 (shown in dotted lines) connects the circuit board 44 to the rotor assembly 12 and the fixed It may be placed between the child assembly 14 and the child assembly 14.

During operation, the majority of the heat generated within motor 10 comes from stator assembly 14. It is something that Maintaining the operating efficiency of the motor 1o and the reliable functioning of the electronic components 46 The heat generated from the stator assembly 14 is transferred to the rotor 12 and electronic components in order to It is beneficial to remove them. Therefore, housing section 28.30 and 32 is made from a material with a high coefficient of thermal conductivity. Also printed wiring circuit board By attaching 44 directly to the thermally conductive end member 38, the electronic component 46 The generated heat is efficiently transferred to the end member. The end member 38 is designed to prevent heat from being transferred to the surrounding environment. and further helps maintain the operation of the electronic components 46 at relatively low temperatures. fins 40 or other configurations.

As shown in FIG. 4, the permanent magnets 20 of the rotor 12 are called pole segments. It is divided into many sections 46 and has mutually opposing magnetic poles, namely north and south poles. are arranged alternately, usually facing radially outward. In a preferred embodiment, three pairs of Poles, or six magnet sections, are employed. The permanent magnets 20 are fixed to each other. six normally wedge-shaped independent magnet sections, or by conventional known methods. It can be composed of any suitable material that can be suitably magnetized.

As mentioned here, the permanent magnet 20 has a magnetic field that is polar-to-pole as described below. comprising one or more substances or a structure of one or more substances that produces There is. Furthermore, the following description relates to a permanent magnet having three pairs of magnetic poles. , fewer or more pairs of magnetic poles may be employed.

The present invention can accommodate 50 or more pairs of poles, such as those typically used in stepper motors. A permanent magnet with only two pairs of poles may be used, or a permanent magnet with only two pairs of poles may be used. Data may also be used. Furthermore, as used herein, field winding, coil winding, and coil The expression may be used to indicate the element or elements of the stator that generate the stator magnetic field. be.

The mutually opposing magnetic poles of the permanent magnet 20 create a pole-to-pole magnetic circuit that A portion is indicated generally at 48. The magnetic flux flows from the N pole face 50 of the magnet 20 to the air gap. The field is emitted through the loop 25 and the coil winding 22 to the field back iron 24, where it is emitted. It usually follows an arcuate path towards the S-polar plane. After that, the magnetic flux is transferred to the winding 22 and and the air gear 25 again to the S pole face 52, and then the rotor It passes through the iron 18 and returns to the diverging polar surface 50.

When a current is suitably applied to the fill winding 22 of the stator 14, a magnetic field is created and its The magnetic field interacts with the pole-to-pole field created by the permanent magnets 20 of the rotor 12. As a result, a reaction torque is generated between the stator and rotor. The rotor 12 is a bearing 34a and 34b, so it can rotate freely and the two magnetic pole faces 50 and and 52 by a distance approximately equal to the length of the arc, or 120 degrees, to apply that torque. decrease. As the rotor 12 rotates that distance, the current flows through the coil windings 22. The current that flows is rectified to provide the next rotational phase. In a 3-phase motor, the rotor is In order to rotate 60 degrees, three different segments of the coil winding called coil phases are required. Current must be passed through the elements in sequence. Continuously passing current through the coil phase Continuous rotation of the rotor is thereby achieved. Torque and horsepower characteristics of motor 10 is the strength of the magnetic field actance created by the coil winding 22 and the permanent magnet 20 Determined by

Typically, the strength of the magnetic field generated by coil 22 depends on the number of filters and the coil It is a function of the current flowing through . The strength of the magnetic field of the permanent magnet 20 depends on the size of the magnet and It is a function of the type of material used. The motor torque is determined by the coil motor in this way. increasing the number of magnets, increasing the current, using larger permanent magnets, etc. can be increased by On the other hand, the torque characteristics of the motor 10 and the efficiency of the motor are also rotor 12 by eliminating magnetic flux losses through the various components of the motor. Modifications can be made such that the magnetic field interaction with the stator 14 is increased.

When the permanent magnet 20 rotates, the fluctuating magnetic field is applied to the field backplane 24 and the bearing. 34a, 34b and near fixed conductive motor elements such as housing assembly 26. It is generated frequently. This fluctuating field is susceptible to losses due to hysteresis and eddy currents. water. The field back iron 24 is made of a winding layer made of highly permeable wire with a small cross-sectional area. Alternatively, these losses can be reduced to the field bulk iron 24 by configuring it with a winding bundle. can be reduced. For more details, please refer to M.A., filed on December 20, 1989. agnetic flux Return Path for an Elec In U.S. patent application Ser. No. 07/453,616 entitled trical Device and is incorporated herein by reference. Small cross-sectional area of each wire reduces eddy currents in the wire and eliminates skin effects associated with high frequency alternating current and its harmonics. minimize the effects. The field back iron 24 is a field winding of a conventional slot motor. Conventional windings, such as those used to produce wire, can be produced using equipment .

To complete the magnetic circuit of rotor 12, a varying magnetic field is passed through field bank iron 24. What should be done is to be affected by the magnetic field and result in magnetic flux loss. There are components that don't even bring benefits. For example, bearings 34a, 34b and Components such as housing end sections 28, 32.

Figure 5 shows a four-pole permanent magnet that can be used in a typical slotless, planless motor. A stone rotor 53 is shown. At both ends of the magnet 54, the N magnetic pole and the S magnetic pole of the permanent magnet 54 are connected. A magnetic flux circuit 56 formed between the poles is schematically shown (indicated by pseudo-lines in the figure). ). As the magnet 54 rotates, the magnetic flux circuit 56 Hysteresis losses and eddy currents pass through constant conductivity motor elements and within these elements. Generates a fluctuating field with flow losses.

According to the invention, such losses are made positive with respect to the rotor 53, as shown in FIG. This can be reduced by using properly positioned magnetically permeable flux shunting elements 58. magnet Magnetically attach a highly permeable element 58 such as a soft iron washer to one side (or both sides) of the By placing the flux circuit 60 above the rotor, the flux circuit 60 is shorted and such losses are reduced. is significantly reduced. As shown in FIG. It's packed. Since the washer 58 moves together with the rotor 52, it has a constant magnetic flux. do. Because the magnetic flux is constant and is confined within Wano/Ya, The field generated by the magnetic flux is also constant. Therefore, in general, the loss associated with a fluctuating field is does not occur, especially bearings 34a, 34b and housing end section 2. 8.32 loss associated with the varying field does not occur either.

Improvements in reducing magnetic flux losses reduce the strength of the magnetic field from pole to pole of the rotor. The reaction torque of the coil winding with the magnetic field increases accordingly. The magnetic flux loss is Runs the motor cold, reducing losses as it is dissipated as heat can be done.

Referring now to FIGS. 7-15, preferred coil construction features of the present invention will be illustrated and described. Ru. First, in FIG. 7, the first coil winding or field winding for the motor 10 is shown. Show steps.

Such a fill winding is connected to one of the phases of the motor 10, for example the first phase of a three-phase motor. It can be used for φ1. In Figure 7, in the first step, the insulated copper wire A continuous conductive wire 6] is used and is wound around a wiring mold 62. The wiring type 62 is Preferably, it is rectangular. The type 62 is the axial length of the permanent magnet 20 (direction of motor axis Z) , and the circumference or arch of one section 46 of the permanent magnet. Width equivalent to the length of the shape or the circumference of the pole face 50.52 of the permanent magnet or the length of the arc Has LRI.

First, a conductor 61 suitable for coil winding, such as a small diameter insulated copper wire, is placed in a type 6 2 and has multiple fibres, such as three coil segments Al, Bl, C1. form a segment. The number of coil segments is proportional to the number of pole pairs of the motor 10. I guess. When winding the conductor 61, the first turn 63 has a height, l, and width LRn. It is assumed to be rectangular in shape. The dimensions of height Lr+ and width LRn correspond to the shape of mold 62. ( The subscript rnJ here represents the coil phase. For example, in coil phase φ1, LR rl is expressed as LRI. The same applies to other fill segments. ) conductor wire 61 is a continuous winding around the mold 62 while forming an adjacent rectangle with each winding. It will be destroyed. This operation determines the cumulative length of adjacent conductor turns (starting with turn 63a) (ending with groove 3b) is repeated until LRI is equal to the first coil phase φ1. Coil Segunton A1 is completed. The next coil turn 64a is a coil segment. The second coil segment Start Ment B. For the remainder of coil segment B, conductor wire 61 is passed through mold 62. It is formed by winding it around the rim many times and ending with a turn 64t). Ko The coil segment C1 is made in the same manner with a distance LR+ from the coil segment B1. It will be done. In this way, three equally spaced coil segments A), B l and C] each have a length LR7 and are adjacent to each other with a distance LR, respectively. Made. These three coil segments with a spacing between each segment A+, F31 and C1 and the interval LR+ following the last coil turn hc+ is one phase (the first (expressed as phase φ1).

The above-described process for winding the first phase φ1 of the coil winding 22 is performed for winding the second phase φ2 and the first phase φ1 of the coil winding 22. The same is carried out for winding the three phases φ3, respectively. However, the second carp When winding the coil phase and the third coil phase, each fill segment An, Bn, and The length and width of C0, as well as the spacing between them, will vary depending on the length of the arc being increased (Model radially away from the data axis Z). Mo When implemented in a motor 10, each successive phase of the coil winding 22 has an increased bow. Must follow the length of the shape. This is explained in more detail below. Ru. As a result, the width LR1,l of the winding mold 62 is such that each coil phase is It increases at intervals corresponding to the positions to be wound. In a preferred embodiment, the coil winding All phases of 22 are coil segments A for each phase of the coil. S　Bn and C1,l Coil wire of appropriate length to make the necessary circuit connections for each of the It is continuously wound onto a single mold 62 while being drawn out. Or each coil The segment may be rolled into separate molds 62 with appropriately sized characteristics.

8 and 9 show that the coil winding 22 is activated similarly to when it receives electrical energy. Coil winding 22 as seen when activated or electrically activated Wiring structure for a typical coil turn forming a coil segment of one phase of Here is an example of the configuration. First, in FIG. 8, the coil phases are electrically connected in series. phase The first fill segment An of the wound conductor is drawn out to form Connected to power supply ■.

Additionally, the conductor is not cut until it reaches the end of the winding of that phase, and is pulled out at the end. and grounded. Typical coil segments forming one phase of coil winding 22 A parallel configuration for coil turns is shown in FIG. Each phase segment 1-An, B, and At the beginning of Cn and Cn, the conductor is brought out and connected to the power supply V. Furthermore, each coil The last conductor winding the segment is pulled out and disconnected. In the latter configuration, each File segment 1 - AnSBn and Co are actually separate circuits or connected as separate circuits. Each coil phase φ1, φ2 and φ3 is one of the above methods. Wired in the same way.

Whether the coils 22 are connected in series or in parallel depends on the purpose and usage of the motor 10. Depends on available power source. If a high voltage, low current power source is available, fill The coils 22 are typically wired in series to minimize power loss throughout.

For low voltage, high current cases, provide the appropriate potential difference across the fill segment Therefore, it is usually desirable to wire the coils in parallel.

Regardless of the wiring configuration, a magnetic field is generated around the fill winding 22 when current is applied. do. When current flows through each turn of coil 22, a magnetic field is created. get closer The fields of the spaced turns join together and touch each other at both ends of the phase segment. Creates a cumulative magnetic field with opposing poles.

The coil winding 22 for three phases is shown in FIG. The winding mold 62 is shown above in relation to FIG. It is a top view and the circuit connections mentioned above are not shown. Coil winding 22 has coil phases φ1, φ2, and φ3, and each coil phase has a coil segment, respectively. Consists of A1, B1, C1; A2, B2, C2; and A3, B3, C3. Ru. Each fill segment such as coil segment A or fill segment Bn Each has a length LRn and a height LRn. Spacing between each coil segment is LRn, and the coil phase such as the adjacent coil phase (the coil phase is the second phase φ1) The spacing between the coil segments, An, B, etc. It's LRn. In some applications, for example, the use of motor 10 may be Depending on the application, the wound coils may be overlapped or the torque characteristics of the motor may be improved. In order to achieve this, the interval between adjacent coil phases may be made smaller than Lqn.

If necessary, the coil 22 on the mold 62 can be removed (or the coil 22 can be removed from the mold 62). heat, such as an insulating varnish that loosely holds the wires of the coil segments together It can also be covered with a conductive, electrically insulating material.

The next step in making the coil winding 22 is to at least partially deform and flatten the winding. The coil segments constituting each coil phase are arranged in a circumferential manner as described below. Allow it to be rolled. Therefore, with respect to FIG. 10, coil winding 22 is Coil turns of wire 22) A+ bottom corners 63a, 63b and coil segment B By rotating 64a, 64b, etc. of 1 counterclockwise, the width direction of the winding die 62 is adjusted. crushed by Figure 62 shows the coil winding 22 and the mold 62 which have been incompletely rotated and are closed. 11. At this point, the incompletely filled mold 62 is removed from the coil winding 22. Preferably, it is removed. However, the coil winding 22 has sufficient dimensional integrity. If so, the mold 62 may be removed before the rinsing step.

The corners 63a, 63b, etc. are rotated approximately 90 degrees in total, and the coil 22 is almost completely rotated. flatten it. This initially caused the The empty space will be filled. In this way, LRl, twice the segment of l A coil segment having a length is provided. The effect of this crushing action is electrically having coil phases with alternating magnetic polarity over each distance LRn when activated The coil winding 22 is to be made. The flattened coil 22 is Covered or re-covered with a fest or similar material that can maintain the temperature and also facilitate heat transfer. covered.

The squishing action just described involves two opposing parallelograms that are offset relative to each other. It is analogous to the relative movement of planes.

As these planes move in opposite directions, the parallelogram collapses and their two The planes of will approach each other and eventually become coplanar. Parallelogram is a square If so, the two couplet planes mentioned above will be completely collapsed and become almost the same plane, and the original A pair of diagonal corners, for example corners 63a163d in FIG. It becomes a relationship. Similarly, with reference to FIG. 11, in fill segment A1.81″ii When a large number of parallel four approximations formed by A pair of corners, such as corner 63b and corner 64e, are adjacent to each other as shown in FIG. If they are in contact with each other, they are on the same plane.

Thereafter, the completed coil 22 is assembled into the rotor assembly 1 as shown in FIG. 2 has sufficient outer dimensions to allow free rotation within the wound coil winding 22. and is wound around the diagonal core 66. After the first coil phase φ1 is crushed, has six times the length of the LRI, and can be wrapped around the core 66 just once. become. Between the first coil phase φl and the coil phase φ2 of the cabinet 2, there is a buried space having a length LR2. Since there is an unresolved space, the second coil phase is The coil phase 1st coil segment l-A that is arranged offset from one fill segment AI? , has. The same applies to the third coil phase φ3, around the core 66. When wound, the coil phase φ3 is separated from the second coil phase φ2 by one pole face. It will be placed in the same direction.

This means that the second coil phase φ2 and the third coil phase φ3 are larger than the previous coil phase. Indicates that it needs to have width and segment length LRn. The second coil phase φ2 is When it is wound, not only the circumference of the core 66 (the circumference increased by the first coil phase φ1) It must be long enough to cover the area. Similarly, the third coil phase φ3 also has a core 66, Sufficient length to completely wind the first coil phase φ1 and second coil phase φ2 You have to have that. By increasing the size of LR2 and LR3, Therefore, the phase segments An, Bn and Bn of the second coil phase φ2 and the third coil phase φ3 and C1 are the arcuate shapes of each pole face, each with an increased diameter, as shown in FIG. can cover the length of

If the torque demand of the motor requires a larger number of coil turns, the coil phase of windings on the core 66 and a previously wound set or sets of windings. It will be rolled further. As mentioned above, the coil phase of each further wound set is , results and 1. has an increased segment length and width LRn, and has an increased segment length and width LRn from the pole face. Adapt to the distance. Each coil phase corresponds to the first cent as described above. are electrically connected in the same way that the coil phases are connected.

In another embodiment of the invention, the winding die 62 has a hexagonal cross section, as shown in FIG. It may have a surface. , : the fill windings 22 are located midway between their respective widths. Created to bend at a point. When crushed, the fill configuration of 42 is rectangular. It is placed on the air gear knob 25 of the motor 10 because it is flatter than the coil of It becomes possible to further increase the number of power filters. Similarly, crush and flatten To facilitate coil winding that can be easily wound Other geometric configurations may also be employed.

By further covering the coil windings with placed and fess.

By drying the previous covering, by the fact that the conductor 61 itself is hard, or After being secured together by other means, the fills 22 are then formed and assembled together. Bonotching (pot ting) etc. The circular core 66 connects the coil winding 22 to a field bag. It is removed before or after being placed in the space circumscribed by the quailon 24. Or, Winding the field bar iron 24 directly onto the completed coil winding 22 You can also do it.

In this way, flexibility in the dimensional tolerances of the field back iron and fill windings can be made to last.

A number of recently proposed single-pair winding configurations [7] The unique advantages of the above-mentioned winding configurations are , the winding process can be done with a conventional winding machine and can be done at low cost. Is Rukoto. The winding configuration of the present invention has a higher To provide an air gear knob 25 for bundling electrical conductor turns with density. , allowing a larger number of coil turns and a stronger stator field in the same area.

To create the magnetic field in the stator 14 necessary to drive the rotor 12, The completed field winding 22 is electrically connected in the manner shown in FIGS. 16 and 17). Connected. The components surrounded by broken lines in FIG. 16 are electronic puffs for the motor 10. A cage 78 is constructed. Other components are traditional wye commutation for 3-phase motors The independent coil phases φ1, φ2 and φ2 of the coil windings 22 connected in configuration 80 It is φ3.

The field windings and rectifier circuits are configured for use with three-phase motors, but are not known to those skilled in the art. Those skilled in the art will appreciate that the present invention can be used with any polyphase motor with the same results. will understand.

The electronics package 78 shown in FIG. 16 mounts directly within the motor housing 26. It is preferable that the For example, formed on printed circuit board 44 and/or 'Nu has been assembled. Electronic packaging up? 4 #Fi from 84 Components of a power circuit for supplying unrouted full-wave rectified power 8 2, the current flowing to the coil phases φ1, φ2, and φ3, and the current flowing to each coil phase φ1, φ2. and a rectifier and power transistor 86 for controlling the current flowing between and φ3; Position sensor 88 for determining rotor/naft 160 angular position, commutation and power An integrated circuit 90 for controlling transistor 86 and for supplying 12 volts DC power. and a power adjustment circuit 92 for supplying power to the position sensor 88 and the integrated circuit 90. Ru. The power circuit components 82 include four diodes D1, D2, D3 and D4. This is a conventional rectifier circuit consisting of Similarly, the adjustment circuit 92 also outputs rectified alternating current. This is a conventional circuit for converting to 12 volts direct current.

Integrated circuit 90 includes a plurality of standard logic elements available from custom IC manufacturers. These elements are used to provide the functionality discussed herein below. children are combined. The inputs, outputs and desired functions of integrated circuits are discussed below. If so, one skilled in the art would be able to design a physical IC with reasonable effort. Or If necessary, those functions may be performed by distributed components. It is possible, but in such a case, the size of the electronic bar or cage 78 may It may become too large to fit within housing 26.

Integrated circuit 90 has several outputs. Its output is a rectifying transistor Three drivers DRIVEL, DRI for switching Q1, Q2, and Q3 VE2 and DRIVE3 and preferably for driving the power transistor QP. is a switching driver PWM PWR whose pulse width is modulated and a common /'T4 force contact. Ground reference COM M ON and 12 volt DC 5UPPLY C0NTR0L including. Integrated circuit 90 has several inputs. Its input is 12pol ) DC 34 force input, three input signals from position sensor 88, and power source 84 The rectifier transistors Q1, Q2, Q3 and and INHI which can be used to latch the power transistor QP in a non-conducting state. BIT signal and numerous motor control inputs (e.g., aimed at controlling speed, direction, and power). (targeted input).

Motor control inputs are C0MM0N, FORWARD/REVERSE, 5PE. ED, PHASE ADVANCES LOW 5PEED LEVEL AD It is JUST. All of these signals are at low power signal logic levels. FOW ARD/REVER3E opens or shorts the signal to COM M ON This is achieved by This applies to constant direction, clockwise and/or counterclockwise applications. /:l internally or reversing motor application for motors This is accomplished through external contact. S PEED is discussed below. In order to regulate the variable speed through pulse width modulation of the rectified power, Provided via an external variable resistor between the speed tap and the signal c o m m o n available. PHASE ADVANCE is an input from an external or internal resistor. Therefore, high-speed operation is improved by adjusting the phase. LOW 5PEED L’ EVEL ADJUST is C0MM0N and LOW 5PEED LEVEL An input from an external or internal fixed resistor between ADJUST and the motor's Fix the maximum speed. 3 additional inputs, RAMP, LINEAR and EXPON ENTIAL offers tilted, linear, and or provide exponential acceleration, respectively. Are all of these inputs external inputs? These are low level logic signals.

Integrated circuit 90 processes the motor control low level logic signal input and outputs the output signal. Determine the characteristics. For example, the integrated circuit 90 receives input signal LOW 5PEED LE Process VEL ADJUST to determine the pulse width that drives the power transistor QP. Determine the maximum duty cycle of the modulated output PWM PWR.

Commutation of coil phases φ1, φ2, and φ3 is described with respect to FIGS. 16-18.

Each coil phase φ1, φ2, and φ3 has a rectifier transistor Q1, Q2, and Q3 connected thereto. They are grounded through each other. Power is supplied to the coil via power transistor QP. It is supplied to a Y-shaped circuit 80. In FIG. 17, rectifying transistors Q1, Q2 and Q 3 are shown as switches S1, S2 and S3, respectively, and the integrated circuit 90 control the coil phases φ1, φ2 and φ3 to a ground reference potential of Connect to 4. The power transistor QP is shown as a switch SP, The rectifying circuit 80 is controlled by the integrated circuit 90 in a manner similar to that of the unfiltered Connects to full wave rectified power.

The location of the rotor 12 relative to the coil phase is such that the rotor 12 is positioned adjacent to the rotor/yaft 16 on the circuit board 4. Detected by three position sensors 88 mounted at 120 degree intervals on the Ru. The position sensor is connected to the rotation of a ring magnet 95 (shown in FIG. 1) on the rotor shaft 6. It is a Hall effect sensor that detects shaft position by detecting displacement. It is preferable. Alternatively, the position sensor reflects light from the reflective surface of the scissorft 16. A photodiode or other equivalent position detection device that detects the shaft position by It can also be used as an output device. The position sensor output follows lines 96, 97 and 98. From these signals, switches SP, 31 are connected to the integrated circuit 90 through Decide whether to open or close S2 and S3. FIG. 18 shows switches SP, S1 , S2 and S3 as a function of the position of the rotor/yaft 16. Indicates the condition. The vertical axis in FIG. 18 indicates the state of the switch. higher signal indicates that the switch is closed, and a lower signal indicates that the switch is open. and The horizontal axis shows the angular position of the foot 16 at the rotor, and the length of the shaft is the total part, approximately 2 revolutions or 720 degrees for the purposes illustrated.

When the rotor is stopped, integrated circuit 90 outputs the FORWARD/REVER The /f aft position information obtained from the position sensor 88 is used along with the 3E motor control input. determine which coil phase should be activated first to start the rotor rotation. Set. Rectification order, i.e. φ1, φ2, φ3, φ1 etc. or φ3, φ2, φ1 , φ3, etc. are determined from the level or sign of the FORWARD/REVER5E input. and rotate it in the desired direction (clockwise/counterclockwise).

The rectification circuit 80, via the rectification and power transistor 86, operates according to the following rectification logic table ( Controlled by integrated circuit 90 as shown in Table 1). In the table, []" indicates a switch in the closed or conducting position, and “0” indicates an open or non-conducting switch. Indicates switch.

Rectification logic table φ1 φl φ2 φ2 φ3 φ3 As can be seen from Table 1, each rectifying phase φ1, φ2, and φ3 is connected to the power switch SP. A current is passed through the coil phase of the coil, and there are ○N and OFF cycles depending on whether the are doing. SP and S3 are closed and power is supplied to coil phase φ3. When the rotor reaches a certain angular position, the electric current is Switch SP is opened and switch S1 is closed (see first column of Table 1).

When Sl is closed, when S3 is opened, the coil phase is held at φ3. Residual power flows to coil phase φ1. This eliminates the need for conventional bypass devices. Using the residual energy from the coil phase φ3 that has been dissipated as heat, the coil phase φ1 begins to be activated. Switch S1 is closed just before switch S3 is opened. Therefore, by flowing current from coil phase φ3 to coil phase φ1, induction spacing can be achieved. The orgasm also disappears. Then, the power switch SP is closed and the current flows into the coil phase φ 1, completely activating the coil phase φ1 (Table 1, second column). life The magnetic field thus created in the polarized coil phase φ1 is transferred from the poles of the rotor 12 to the poles. interacts with the magnetic field to rotate the rotor by an angular distance of about two pole faces or 120 degrees. generates a reaction torque that causes the rotation.

After that, when the power switch SP is opened and current no longer flows to the rectifier circuit, the switch switch S2 is closed (third column). When switch S1 is opened, the previously activated The residual energy held in coil phase φ1 flows to coil phase φ2, Begins its active state. When the power switch SP is closed again, the coil phase φ2 is activated to produce a magnetic field, causing the rotor 12 to rotate an additional 120 degrees (column 4). . Then, when the power switch SP is opened, S3 is closed and 82 is opened, the coil The residual power from phase φ2 is used to activate coil phase φ3 (column 5). power is restored (column 6), the coil phase φ3 interacts with the magnetic field from pole to pole of the rotor 12. The interacting magnetic fields are again generated to complete one 360 degree rotation of the rotor. In this order The sequence is repeated continuously to supply rectified power to the motor 10.

The coil phase that was last activated as determined by the rotational position of the shaft At the same time or immediately after the rectifier switch from SP is opened, the power switch SP is closed and current flows to the next coil phase in sequence. Or rectifier circuit junction point 9 Since the potential voltage between 9 and 11 [84 is measurable, the potential difference reaches approximately zero Then, the power switch SP is closed.

The switching of the rectifier circuit as described above is actually performed using transistors Q1, Q2 and Q3. carried out by. Shaft position signal 96.97 received by IC90 ．． 98, the coil phase φ1 should be conducted to ground 94 (in FIG. switch S1 is closed), a high signal or active A signal is output from DRIVE+ through line 100 to transistor Ql. Ru. This drives the transistor Q1, which is connected to the coil phase φl and becomes 0. Since line 102 is grounded, current flows through coil phase φ1. other carp Switching for phase φ2 and φ3 is performed using transistors Q2 and Q3, respectively. done in the same way.

IC90 has PWM PWR (life 106) low 1. S signal or bind active state, current is passed through line 104 by transistor QP. and flows into the coil phase.

The speed at which the rotor 12 rotates varies with the coil phases φ1, φ2, φ3 over the rotation period. It can be determined by the average power given. Motor speed can be variable or It is a function of a fixed signal input, e.g. Therefore, it is a function that can be determined. The signal is the input S P E E D. integrated circuit 90. The average power to the coil phase is determined by the power transistor QP. determined or controlled by pulse width modulating the power supplied to the coil phase. can be Based on the signal sent to the 5PEED input of integrated circuit 90, The integrated circuit then generates a pulse width modulated signal PWM that drives the power transistor QP. Determine the pulse width of PWR.

As a result, the rectifier circuit 80 is configured as shown in FIG. <Depending on pulse width modulation power power is actually supplied. Basic chip of PMW PWR signal from integrated circuit 9δ 5 The knob frequency is preferably within the range of 20-30 kilohertz (Khz). However, higher or lower frequencies can also be used. 20~30Kh Since the chop frequency of z is at least 10 higher than other system time constraints, , which simulates essentially constant power input to the rectifier circuit 80.

The proportion of the chop frequency duration that power is applied is the proportion of the chop frequency duration that is fed to the rectifier circuit 80. Determine the equalized power. The top signal in Figure 19 is 20 percent of the chop frequency. , thus an example of a signal in which the mold force is applied for a duty cycle of 20 percent. It shows. As a result, motor 10 operates at 20 percent of maximum speed.

The middle and lower signals represent examples of 50 and 80 percent duty cycles. are shown respectively.

In the preferred embodiment, the speed of the motor is determined by the duty of power to the rectifier circuit 80. Continuously changing between the minimum value and the oldest value by changing the cycle Can be done.

Motors can also interchangeably use alternating current (AC) or direct current (DC) power sources. It can also be configured to work.

Produces the same output torque at the same speed for different power supplies, i.e. AC and DC Therefore, the field winding 22 can also be configured as shown in FIG. 1/4 For horse camors, ACII power requirements are on the order of approximately 115 VAC at 2 amps. and the DC power requirement to produce the same horsepower is approximately 12 VD at 18.5 amps. It is C. Therefore, in order to have the same output torque, each phase of the rectifier circuit 80 must have two set of windings, i.e. one is ACil! one for DCII power, the other has a winding for DCII power. must be done. (AC coils are indicated by X, DC coils are indicated by Yn. Ru. ) As mentioned above, the output torque is a function of the number of coil turns and the applied current. It is a number.

The rectifier circuit has two switching elements SA and SB, and each rectifier circuit has two switching elements SA and SB. Using coil phases φl, φ2 and φ3 with flow transistors Q1, Q2, Q3 It is reconfigured as a Y-shaped circuit. If configured to operate on d.c. , as shown in Figure 20, switch SB is open and switch SA is connected to the AC power supply. It is located in a position that bypasses the illumination set x0. Therefore, the DC power is DC coil set, It flows only through Y0. DC coil set Y. typically has a higher DC amperage. AC coil set X to handle the number of pairs. wrapped with wire of a lower gauge than ing. Power flow bypasses the AC coil set through line 110 . When configured to operate on AC power, switch SB is closed. (not shown), the switch SA cooperates with the switch SS, and the AC coil safety F It is in a position to conduct current through Xn. For alternating current, use AC coil set X. as well as It flows through both DC coil sets Yn.

When configured to operate on DC power, power conditioning circuit 92 is bypassed. A 12 volt DC3II power is supplied to the integrated circuit 90 and the position sensor 88. Ru.

In either AC or DC structure, the current flow to the rectifier circuit is regulated by power transistor QP controlled by 90. power tran The power supplied to transistor QP is an unfiltered full-wave rectifier ff, Ac:! 4112, or a switch that can be positioned to supply power from DC power #114. Determined by SM. The operation of switches SA and SB is similar to switch SM. The former automatically configures AC or DC'N power depending on the position of switch SM. Preferably, it is configured dynamically. Switch SM is located outside the motor. be operated by the user or located internally to insert the power supply or power cord. be operated by etc.

Can be done.

Mizumoto i11's features are Sumino dress, branless, and large air gear. Although the above explanation refers to an electromechanical device in the form of an electric motor, Many of these features apply to other motors, generators and similar electrical and electromechanical devices. It will be understood by those skilled in the art that it may also be used with respect to

For example, the rectifying structures described herein are compatible with typical slots, to name a few. It can be used in equivalent devices to be equivalent.

FIG. 13 FIG. 17 PWM L-1-7171-1-fLfL 20% de"-147471L-" 20% electric f) entry p73・17゛1 station 1 FIG. 19 1 place! Slotless, brushless, large air gear, electric motor (10) with a magnetic field A stator (14) with a winding (22) and a field back iron (24) and a fixed a shaft (16) and a permanent mounted thereon; It has a rotor (12) with permanent magnets (20). The field winding consists of multiple It consists of polygon-shaped turns arranged at offset points, forming a roughly flat winding. ing. The field winding turns (83a, 63b, 64a, 64b) are rectangular or is preferably hexagonal in shape. Also, the previously activated field winding (22 ) is then activated by the field winding (22). The section J has a rectifying structure that dissipates, and this rectifying structure is used to control the motor. integrated circuits (90) for use in both AC and DC power supplies (84, 92) A suitable winding configuration and a magnetically permeable flux shorting element (58) that increases efficiency are disclosed. It is.

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Claims (1)

[Claims] 1. A stator having a field winding and a field back iron, the field winding comprising: Multiple successively staggered windings so that when unwound they are nearly flat windings. a stator having polygon-shaped turns placed; a permanent magnet disposed within the stator and mounted on the shaft and thereon; rotor with slotless, brushless and large air gap electric motor. 2. The motor of claim 1, wherein the polygonal turns are rectangular. 4. The motor of claim 1, wherein the polygonal shaped turns are hexagonal. 5. The motor according to claim 1, wherein the plurality of turns are electrically connected in series. Ta. 6. wherein the individual segments of the plurality of turns are electrically connected in parallel; The motor according to claim 1. 7. The motor of claim 1, wherein the field winding is insulated copper wire. 8. 2. The field winding of claim 1, wherein the field windings are electrically connected to form a three-phase winding. motor. 9. 9. The field winding is electrically connected to a Y-shaped rectifier circuit. motor. 10. 10. The motor of claim 9, wherein the commutation circuit is controlled by an integrated circuit. 11. spirally winding the wire around a mold in the shape of a polygon; leaving an unwrapped space at a predetermined distance; has a length of the predetermined distance; Continuously staggered arrangement of flattened windings having approximately polygonal shapes; Tighten the two sides of the mold so that the unrolled turns fill the unrolled spaces. a step of winding the flattened winding to form a hollow cylinder; P, A method for creating a field winding for an electric motor, comprising: 12. The spirally wound wires of a predetermined distance are electrically connected in series. 12. The method of claim 11, further comprising the steps of: 13. The spirally wound wires of a predetermined distance are electrically connected in parallel. 12. The method of claim 11, further comprising the step of connecting. 14. A plurality of wires having a predetermined distance are electrically connected to form a Y-shaped joint. 12. The method of claim 11, further comprising the step of forming. 15. Covering the flattened windings with a material to secure the flattened windings together. 12. The method of claim 11, further comprising the step of determining. 16. The winding step includes winding the flattened winding around a cylindrical core. 12. The method of claim 11, comprising: 17. a field back that surrounds the field winding by wrapping a magnetically permeable material around the field winding; 17. The method of claim 16, further comprising forming an iron. 18. A stator having a field winding and a field back iron, the field winding comprising: It is configured in a Y shape and has a rectifier switch between each end of the Y shape and ground. and a stator having a power switch between the common junction point of the Y-shape and the power supply, the stator a rotating shaft having a shaft and a permanent magnet mounted thereon; a trochanter and an integrated circuit controlling the switch; electric motor with 19. the rectifying switch is a transistor controlled by the integrated circuit; The motor according to claim 18. 20. the power switch is a transistor controlled by the integrated circuit; The motor according to claim 19. 21. 19. The motor of claim 18, wherein the power source provides alternating current to the power switch. Ta. 22. 19. The motor of claim 18, wherein the power source provides direct current to the integrated circuit. 23. The power switch controls the pulse width of the power supplied to the common junction of the Y-shape. 21. The motor of claim 20, wherein the motor is modulated to provide variable speed rotation of the rotor. 24. The rectifier switches are controlled by an integrated circuit to operate substantially sequentially. 21. The motor according to claim 20. 25. The power supply to the Y is turned off while the rectifier switch is switched. 25. A motor according to claim 24, interrupted by a force switch. 26. a stator having a field winding and a field back iron, and a shaft, a permanent magnet mounted thereon, and a shaft disposed within the stator; By short-circuiting the magnetic field spreading from both axial sides of a permanent magnet, a rotor having means for completing a magnetic circuit with electric motor with 27. said means for short-circuiting said magnetic field on said shaft on both sides of said permanent magnet; 27. The motor of claim 26, comprising a pair of magnetically permeable elements attached thereto. 28. The field back iron is made from a magnetically permeable wire having a relatively small diameter. 27. The motor according to claim 26. 29. The field back iron is wound using the magnetically permeable wire. The motor according to claim 28. 30. 28. The motor of claim 27, wherein the magnetically permeable element is a soft iron lasher. 31. A stator having a field winding and a field back iron, the field winding comprising: It is configured in a Y shape and has a rectifier switch between each end of the Y shape and ground. a stator having a power switch between the common junction of the Y and the power supply; A rotation having a shaft and a permanent magnet placed in a stator and mounted on it. trochanter, Polyphase motor with. 32. 32. The motor of claim 31, wherein the commutation switch is a transistor. 33. 33. The motor of claim 32, wherein the power switch is a transistor. 34. further comprising detection means for detecting the rotational position of the shaft; A motor according to claim 33. 35. 35. The motor of claim 34, further comprising an integrated circuit. 36. The integrated circuit controls the commutation switch as a function of the rotational position of the shaft. 36. The motor of claim 35, wherein the motor controls the switch and the power switch. 37. The integrated circuit controls the commutation switch as a function of the rotational position of the shaft. as a function of the potential voltage difference between the common junction and the power supply, and 3. Controlling the power switch as a function of the rotational position of the shaft. 5. The motor according to 5. 38. 34. The motor of claim 33, wherein the power source provides alternating current to the power switch. Ta. 39. 34. The motor of claim 33, wherein the power source provides direct current to the power switch. Ta. 40. Claim 35, wherein the power supply supplies direct current to the integrated circuit and the detection means. The motor described in . 41. 35. The module of claim 34, wherein the detection means includes a Hall effect sensor. Data. 42. The pulse width of the power supplied to the common junction of the Y by the power switch 38. The motor of claim 37, wherein the motor modulates the rotor to define variable speed rotation of the rotor. . 43. A stator having a field winding and a field back iron, the field winding comprising: Sections for activation by rectified alternating current or direct current and sections for activation by direct current only. a stator having a section for activation; disposed within the stator and having a shaft and a permanent magnet mounted thereon; rotor, electric motor with 44. 44. The motor of claim 43, wherein the field winding is supplied with alternating current. 45. 44. The motor of claim 43, wherein the field winding is supplied with direct current. 46. The field winding supplies either AC power or DC power. Therefore, the power will automatically configure the claim to be powered. The motor according to item 45. 47. providing power to a first field winding phase; powering the first field winding phase; discharging the retained energy of the first field winding phase into the second winding phase; a step of dispersing; and commutating the polyphase motor, sequentially including the steps of: powering the second winding phase; How to do it. 48. 48. The method of claim 47, further comprising detecting a rotational position of the rotor. How to put it on. 49. The step of interrupting the power is performed when the rotor has rotated by a predetermined angle. 49. The method of claim 48, wherein the method is performed. 50. 50. The method of claim 49, wherein the predetermined angle is approximately 120 degrees. 51. The step of providing power to the second field winding phase comprises 48. The step is performed when the voltage of a portion of the field winding becomes approximately zero. the method of.