KR200273510Y1 - Brushless dc motor having the resinoid molded stator - Google Patents

Abstract

The present invention relates to a resin mold stator, such as a brushless DC motor;

A resin mold stator such as a brushless direct current motor including a fixed magnetic flux generator such as a brushless direct current motor; The stator is formed by placing a coil winding body in a shape of a standardized resin compound and injecting and fixing the resin compound. The stator is placed in a shape of a shaped resin compound. It is characterized in that by injecting the powder fixed, the mold stator is configured as a circumferential magnetic flux motor (RFPM) and an axial magnetic flux motor (AFPM), respectively, a casing for fixing the shaft and mounting the rotor according to the purpose of use As an additional feature to be applied to this rotating or configuration to secure the casing and rotate the shaft; It can be applied to circumferential flux motor (RFPM) and axial flux motor (AFPM). The resin mold stator improves the winding density of coil winding per unit volume, so that the magnetic flux density between the rotor and stator air gap is also increased. It is possible to increase the ratio of the driving force per unit weight of the electric motor, and to make the length in the axial direction very compact, thereby having various applications.

Description

Brushless dc motor having the resinoid molded stator

The present invention relates to a resin mold stator, such as a brushless DC motor, and to providing a configuration suitable for applying to a brushless DC motor.

More specifically, as a slotless stator with improved configuration of a conventional motor, it is composed of casting epoxy resin system + magnetic body powder + coil type, By using the epoxy resin for casting and magnetic powder powder with high permeability in the stator of the motor, the magnetic permeability can be increased by substituting the iron core, and the high density magnetic flux can be used to provide magnetic materials such as a compact and highly efficient electric motor. It is for.

Background Art Various types of electric motors have been devised for use as a power source for driving.

In the conventional motor, the stator is mostly composed of a core and the magnet is disposed on the rotor, and the magnetic and weight of the motor are long and the width of the motor is large by configuring the magnetic flux and current by the magnet. There was a limit to shortening.

Therefore, due to the above-described problems, the ratio of driving force per unit weight is low, and there is a problem in that the applicability of various practical applications is lowered because it is not easy to mount in a narrow space.

In addition, since the circumferential flux brushless direct current motor (RFPM (Radial Flux Permanent Magnet) brushless motor) must be connected to the drive shaft in parallel or at right angles and provided with a connection mechanism, the cost of the unnecessary member must be increased and the mounting space must be secured. There was a problem that the compactness is limited.

In recent years, motors used in various control mechanisms require more compact, compact, precise, and high-efficiency configurations, and require high design and accurate characteristics of each element to satisfy these requirements.

Currently, brushless motors are used not only for power but also for control. Because of these uses, researches on brushless motors are actively conducted not only for small size, light weight, high efficiency and high power but also for improving control performance. If the control characteristics of the motor are improved, the driving mechanism of the motor can be simplified and the machine can be miniaturized and the cost can be saved.

The characteristics of such a motor have become a very important design point in mechanical design.

Recently, due to the demand for high performance of the motor, much attention has been paid to the torque pulsation characteristics as well as the output characteristics of the motor.

Torque pulsation characteristics have been proposed to reduce the pulsating torque by skewing the motor stator core slot, and is still widely used as a main method for reducing torque pulsation.

However, this method is effective in the presence of slots and is effective in reducing cogging torque, but not in motors without cogging torque, such as coreless.

The use of the core in the stator of a brushless motor, which is generally used, affects the vibration and noise of the motor due to pulsation as well as electrical losses. In addition, due to mechanical complexity, the low density of the coil winding lowers the force generation ratio per unit weight of the motor, thereby reducing the overall efficiency of the motor.

In coreless motors, coil windings are densely distributed evenly, so vibration and noise of the motor due to pulsation are less affected than those using cores.

On the other hand, the disadvantage of the coreless motor is that the mechanical strength is not strong and the air gap is relatively large, the magnetic flux density in the air gap is low, affecting the output. In order to reduce this effect, the recent development of rare earth magnets (Nd-Fe-B) having a high energy density has been a lot of these disadvantages.

The present invention relates to an improvement on the existing electric motor used as the power source described above, to compensate for the disadvantages of the core (Core), coreless (Coreless) type of the motor was the main form of the motor in the past,

It is slotless type and provides resin mold stator brushless DC motor composed of casting epoxy resin system + magnetic body powder + coil type stator. do.

The brushless DC motor of the present invention uses magnetic body powder and casting epoxy resin system, which have high permeability of the stator, compared to the conventional electric motor. The density is improved, and the use of the finished core can improve the iron loss of the motor and the low density of the coil winding.

In addition, by using the epoxy resin compound and the magnetic powder for the mold in the stator of the brushless motor, the ratio of the driving force generated by the motor per unit weight was greatly improved.

In addition, since the shorter structural length by improving the core and coreless shortcomings used in general electric motors, the inertia is small, and the light weight is small, so that it can have various uses such as various control motors and power motors. do.

1 shows the basic structure of a brushless DC motor to which a resin mold stator such as a brushless DC motor of the present invention is applied, and shows the principle and configuration of a coiled circumferential flux motor and an axial flux motor, respectively. Longitudinal section view.

2 is a cross-sectional view showing a stator of a coil-type circumferential magnetic flux motor and an axial magnetic flux motor of another embodiment to which a resin mold stator such as a brushless DC motor of the present invention is applied.

3 is an exploded view showing a part of the rotor and the stator in the brushless DC motor of the configuration in which a resin mold stator such as a brushless DC motor of the present invention is applied.

4 is an exemplary plan view of a winding body in a stator configuration of an axial flux brushless DC motor to which a resin mold stator such as a brushless DC motor of the present invention is applied.

5 is an exemplary plan view and a partial perspective view of a winding body of the stator configuration in a brushless DC motor of a circumferential flux to which a resin mold stator such as a brushless DC motor of the present invention is applied.

6 is a flowchart illustrating a process of manufacturing a resin mold stator, such as a brushless DC motor of the present invention.

Explanation of symbols on the main parts of the drawings

E: Casting Epoxy Resin System

MP: Magnetic Body Powder

CO: Coil

G: Gap

S: Shaft

Y: York

C: Casing

M: Permanent Magnet

Brushless DC motor of the present invention devised to achieve the above object;

A resin mold stator such as a brushless direct current motor including a fixed magnetic flux generator such as a brushless direct current motor;

The stator is basically characterized in that the coil winding body is placed in a shape of a standardized resin compound and the resin compound is injected and fixed.

Further, in a resin mold stator such as a brushless DC motor including a fixed magnetic flux generating device such as a brushless DC motor; It is a specific feature that the stator is formed by placing a coil winding body in a shape of a standardized resin compound and injecting and fixing the resin compound and magnetic powder.

In addition to this, the resinous mold stator is characterized in that it is configured integrally with a sensor, a rectifying piece, etc. that can detect the position of the magnetic pole in the mold stator,

The mold stator is configured as a circumferential magnetic flux motor (RFPM) and an axial magnetic flux motor (AFPM), respectively, according to the purpose of use. It is a main structural feature applied to the structure to rotate.

The configuration and operation effects of the axial flux brushless DC motor of the present invention together with the accompanying drawings will be described in more detail.

1 shows a basic structure of a brushless DC motor to which a resin mold stator such as a brushless DC motor of the present invention is applied, and a longitudinal cross-sectional view showing a principle configuration of a coiled circumferential flux motor and an axial flux motor, respectively. 2 is a cross-sectional view showing a stator of a coiled circumferential flux motor and an axial flux motor of another embodiment to which a resin mold stator such as a brushless DC motor of the present invention is applied, and FIG. 3 is a brush of the present invention. 4 is an exploded view showing a part of the rotor and stator of a brushless DC motor in which a resin mold stator such as a lease DC motor is applied, and FIG. 4 is an axis to which a resin mold stator such as a brushless DC motor of the present invention is applied. Exemplary plan view of a winding body in the stator configuration of a directional flux type brushless DC motor, FIG. Exemplary planar and partial perspective views of a stator configuration in a circumferential flux brushless DC motor to which a resin mold stator such as a brushless DC motor of the present invention is applied, FIG. It is a flowchart explaining the process of manufacturing an oil-based mold stator.

In the resin mold stator of the brushless DC motor of the present invention,

For example, the configuration of the stator used in the brushless DC motor will be described.

A circumferential flux motor (1: RFPM: Radial Flux Permanent Magnet-Motor) and an axial flux motor (100: AFPM: Axial Flux Permanent Magnet-Motor) will be described.

The circumferential flux-type electric motor 1 constitutes the rotor 10 which is fixed to the shaft 2 and rotates as a magnet 11 which is axially supported and fixed to the shaft 2 in the figure, and the gap G is shown. The tubular stator 30 fixed to the inner side of the casing 20 has been configured as the core or coreless coil winding 31.

In addition, the axial magnetic flux motor 100 is as shown in the right figure of FIG.

The stator 130 fixed to the fixing shaft 102 fixed to the fixing member and mounted on the fixing member to prohibit rotation is constituted as the coil winding 131, and the mounting plate 123 inside the rotating casing 121 is provided. A plurality of plate-shaped magnets 122 mounted on the wall are attached to the rotor 120 and used as a rotation driving device such as a wheelchair.

In the above-described configuration, each of the coil windings 31 and 131 has a problem described above by configuring only the coil winding body of the core or coreless structure which is conventionally an iron core.

In the resin mold stator of the present invention, such as a brushless DC motor, the main feature of the coil winding bodies 31 and 131 is to provide a new manufacturing method.

As the magnets 11 and 122 are shown,

It has a through hole in the circumferential flux type motor 1 and the axial flux type motor 100 and is used as magnetized with various shapes and magnetic poles, and designed on the surface of the electric steel sheet of the rotor 10, 120. It is attached after magnetizing in the number of poles and shape corresponding to the capacity and rotation speed. Magnets (11,122) are determined according to the purpose of the motor, and the shape of the magnet is accommodated separately by assembling after the multi-pole co-rotator or two-pole individual magnet.

In constructing the coil windings 31 and 131 of the stator 30 and 130,

Prepare a mold having a complete mold of the stator. (200)

The coil coil wound body is placed in the mold, which is the completed mold, and fixed as a suitable jig (210).

Resin filler such as epoxy resin having good injection property is injected into the space of the fixed coil winding body (220).

The magnetic powder is mixed with the resin filler and stirred by vibration or the like. Or mixed with the resin filler is stirred and injected. (230)

The mold is heated and pressurized to obtain a compressed and dried stator.

The mold is released to obtain completed stators 30 and 130 (250).

Resin mold stators such as brushless DC motors of the present invention manufactured in such a configuration use epoxy resin compounds for various types of molds as fixing means for forming a stator by forming a stator mold.

The stator is made of a magnetic body in which the magnetic powder is contained, and the coil winding of the desired design is disposed in a mixture of the resin and the magnetic powder.

As a stator for a circumferential flux-type motor and a stator for an axial flux-type motor, as compared with a conventional core or coreless motor,

(1) Since the design considerations for the core are unnecessary, the excretion density of the winding can be greatly increased,

(2) In order to improve the magnetic flux density in the air gap (coil free space), stator and rotor as motor components are supported by mixing magnetic material powder with high permeability and epoxy resin compound for molding and supporting stator coil winding body. The magnetic flux in the direction parallel to the axis and the magnetic flux in the direction parallel to the circumferential direction are generated between the pores of, which greatly increases the driving force.

(3) Therefore, the coil winding of the stator of the brushless DC motor of the present invention is a epoxy resin compound and a magnetic powder type for casting, and has a characteristic that torque is generated by the magnetic flux and the current of the winding. It has the same magnetic flux focusing characteristics and driving force increasing characteristics, but also enables space utilization and compactness.

(4) In addition, the resin mold stator of the brushless DC motor of the present invention may be configured in various forms, such as a circumferential flux type motor and an axial flux type motor, depending on the purpose of use. All kinds of batteries having a core and a core have general versatility applicable to a component.

Although the epoxy resin compound for the above-mentioned mold is mentioned as an epoxy resin in the present invention, various kinds of resins such as epoxy-based, resin-based, and perenol-based resins can be used to meet the design purpose.

As the thermosetting resin, an epoxy resin, a phenol resin, a polyimide resin, or an epoxy resin is preferable, and as the epoxy resin, a novolak-type epoxy resin such as a phenol novolak type or a cresol novolak type, and dicyclopentadiene modified It is possible to use an alicyclic epoxy resin or the like. Since the epoxy resin is used in combination with a curing agent to cure with a three-dimensional thermosetting material, its performance largely depends on the selection of the curing agent.

As the magnetic powder, iron, cobalt, nickel, and alloys thereof are typical, and powder powder having excellent magnetic properties is used.

As a result of the experiment, the resin mold stator such as the brushless DC motor of the present invention having the above-described configuration has a volume ratio of the resin for the mold and the magnetic powder of 100%: 10 to 60%, and the intended use (drive force, size, Components of the magnetic powder, etc.), therefore, the volume ratio can be configured to be fluid.

FIG. 2 shows only the resin mold stator of the circumferential flux type motor 1 and the axial flux type motor 100 of the brushless DC motor.

Each of the forms produced and completed by the method described above is shown.

FIG. 3 is a local view showing an A-A cross section of a circumferential magnetic flux motor 1 of a brushless DC motor,

The circumferential flux-type motor 1 shows the use of a stator manufactured by the above-described method in constructing a tubular stator 30 fixed to the inside of the casing 20 with a gap G. .

The cross section of the rotor and the stator is shown. Since the ratio of the area of the gap G and the winding area to the cross section of the magnet 11 is constant, it can be expressed as shown in the figure.

Correspondingly, in the case of the stator 130 (axial magnetic flux motor 100) fixed to the casing 20 or fixed to the shaft S as the stator 30 that provides rotational force in cooperation with the magnet 11 above. ) Consists of a resin mold stator.

In this configuration, since the ratio of the force per unit weight of the motor is increased, the stator windings are densely disposed to be compactly housed in the casing.

4 and 5 show an exemplary configuration of the resin mold stator winding body of the axial magnetic flux motor 100 and the circumferential magnetic flux motor 1 of the present invention.

As described above, the stator of the present invention can increase the generation ratio of the force per unit weight due to the increase in the magnetic flux density in the air gap by using the magnetic powder having a high permeability without using the iron core.

In addition, this configuration has a characteristic that can reduce the weight of the motor itself.

Since the motor is slotless, the assembly of the winding connects the coils of each phase in series and in parallel, and the number of coils is correlated with the permanent magnet and the coil diameter. The assembly method of winding is to insulate each phase with high strength insulating resin.

As described above, the resin mold stator of the brushless DC motor of the present invention is composed of an epoxy resin compound, a magnetic powder, and a coil winding body for a mold.

The resin mold stator motor configured by this can be applied to the circumferential magnetic flux motor (RFPM) and the axial magnetic flux motor (AFPM), and the resin mold stator improves the winding density of the coil winding per unit volume. The magnetic flux density between the rotor and stator voids is also increased.

As described above, an electric motor constituted by a resin mold stator such as a brushless DC motor of the present invention improves the ratio of the driving force per unit weight of the electric motor, and its length in the axial direction can be made very compact. In addition to having properties, it is a useful design having a very wide applicability such as being suitable for a wide speed range of low speed to high speed.

Claims (5)

A resin mold stator such as a brushless direct current motor including a fixed magnetic flux generator such as a brushless direct current motor; And a stator configured by placing the coil winding in a shape of a standardized resin compound and injecting and fixing the resin compound to form the stator. 2. The resin mold stator of claim 1, further comprising: a resin mold stator such as a brushless DC motor including a stationary magnetic flux generator; A resin mold stator such as a brushless DC motor, wherein the stator is formed by placing a coil winding body in a shape of a shaped resin compound and injecting and fixing the resin compound and magnetic powder. The method of claim 1, The stator is placed in a shape of a standardized resin compound, and the coil winding body is placed and fixed by injecting magnetic powder into the resin compound, and the coil winding body is not placed in a slot. Resinous mold stator. The method according to any one of claims 1 to 3, The resin mold stator is a brushless DC motor, characterized in that it is composed of a sensor, a commutation piece and the like to detect the position of the magnetic pole in the mold stator. The method according to any one of claims 1 to 3, The mold stator is configured as a circumferential magnetic flux motor (RFPM) and an axial magnetic flux motor (AFPM), respectively, according to the purpose of use, the shaft is fixed and the casing for mounting the rotor rotates, or the casing is fixed and the shaft is fixed. A resin mold stator such as a brushless DC motor, which is applied to a rotating structure.