WO2020114527A2 - 带有位置编码器的外转子直驱电机 - Google Patents

带有位置编码器的外转子直驱电机 Download PDF

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Publication number
WO2020114527A2
WO2020114527A2 PCT/CN2020/080245 CN2020080245W WO2020114527A2 WO 2020114527 A2 WO2020114527 A2 WO 2020114527A2 CN 2020080245 W CN2020080245 W CN 2020080245W WO 2020114527 A2 WO2020114527 A2 WO 2020114527A2
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WIPO (PCT)
Prior art keywords
stator
motor
circuit board
printed circuit
outer rotor
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PCT/CN2020/080245
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English (en)
French (fr)
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WO2020114527A3 (zh
Inventor
陶骋
杨莹
宋红刚
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赛卓电子科技（上海）有限公司
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Priority to US16/960,549 priority Critical patent/US11368064B2/en
Publication of WO2020114527A2 publication Critical patent/WO2020114527A2/zh
Publication of WO2020114527A3 publication Critical patent/WO2020114527A3/zh

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
    • H02K11/20—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection for measuring, monitoring, testing, protecting or switching
    • H02K11/21—Devices for sensing speed or position, or actuated thereby
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/27—Rotor cores with permanent magnets
    • H02K1/2786—Outer rotors
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12—Stationary parts of the magnetic circuit
    • H02K1/16—Stator cores with slots for windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
    • H02K11/20—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection for measuring, monitoring, testing, protecting or switching
    • H02K11/21—Devices for sensing speed or position, or actuated thereby
    • H02K11/225—Detecting coils
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K17/00—Asynchronous induction motors; Asynchronous induction generators
    • H02K17/42—Asynchronous induction generators
    • H02K17/44—Structural association with exciting machines
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K5/00—Casings; Enclosures; Supports
    • H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
    • H02K5/16—Means for supporting bearings, e.g. insulating supports or means for fitting bearings in the bearing-shields
    • H02K5/173—Means for supporting bearings, e.g. insulating supports or means for fitting bearings in the bearing-shields using bearings with rolling contact, e.g. ball bearings
    • H02K5/1732—Means for supporting bearings, e.g. insulating supports or means for fitting bearings in the bearing-shields using bearings with rolling contact, e.g. ball bearings radially supporting the rotary shaft at both ends of the rotor
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
    • H02K2203/03—Machines characterised by the wiring boards, i.e. printed circuit boards or similar structures for connecting the winding terminations
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2205/00—Specific aspects not provided for in the other groups of this subclass relating to casings, enclosures, supports
    • H02K2205/03—Machines characterised by thrust bearings

Definitions

  • the invention relates to an external rotor direct-drive motor with a position encoder.
  • direct-drive motors directly couple moving loads and motor movers, thus eliminating the need for connecting mechanisms such as reducers, gear boxes, and pulleys, thus making the entire system efficient, low-loss, high-speed, High reliability, maintenance-free, high rigidity and quick response, no need for lubrication, quiet operation and other advantages.
  • the direct drive motor has a large output torque, it is also called a torque motor.
  • the design method of external rotor direct drive motor is generally adopted.
  • the outer rotor motor means the rotor is the outer permanent magnet pole and the inner coil part is fixed; the inner rotor motor is the rotor is the inner coil part and the outer permanent magnet pole is fixed.
  • the output torque of the outer rotor motor is much larger than the output torque of the inner rotor motor. Therefore, in order to maximize the output torque, many designers generally adopt the design method of the outer rotor direct drive motor.
  • the position encoders used in many external rotor direct-drive motors on the market are simple three Hall switches. Its most basic function is to collect position signals for three-phase current switching of the motor, and the resolution of the position encoder Limited to the number of motor pole pairs, for example, the number of motor pole pairs is 1, then the motor can only get 6 position signals for one revolution, the resolution is much lower than the ordinary servo motor, so it can not accurately reflect the position information of the motor rotation, making The control system cannot effectively control the parameters such as motor efficiency, speed and output torque, and causes energy waste.
  • the present invention aims to provide an outer rotor direct drive motor with a position encoder that solves the above technical problems.
  • the outer rotor direct-drive motor with a position encoder of the present invention includes an outer rotor and a stator disposed in the outer rotor; wherein the stator includes: a stator chassis; a stator printed circuit board, the A stator printed circuit board is provided on one side of the stator chassis, and at least an excitation coil and a receiving coil are printed on the stator printed circuit board; a stator winding is provided on the stator printed circuit board; The outer rotor changes the coupling strength between the exciting coil and the receiving coil.
  • the outer rotor includes: a motor housing; a motor rotating shaft, one end of the motor rotating shaft extends into the motor housing and is connected to the bottom of the motor housing; a permanent magnetic steel, the permanent magnetic steel is provided in the An inner wall of the motor casing; an induction mechanism, the induction mechanism is provided on the motor casing, the induction mechanism corresponds to the excitation coil and the receiving coil; wherein the induction mechanism changes the excitation coil and The coupling strength between the receiving coils.
  • the induction mechanism includes a rotor printed circuit board, the rotor printed circuit board is disposed on the motor housing, and a plurality of periodically repeating electrical conduction in the circumferential direction are printed on the rotor printed circuit board Material scale area.
  • the scale region of the conductive material printed on the rotor printed circuit board vertically overlaps the excitation coil and the receiving coil printed on the stator printed circuit board.
  • the induction mechanism includes a saw-tooth structure, which is periodically repeated, and is provided at the bottom of the side wall of the motor housing.
  • the sawtooth structure at the bottom of the side wall of the motor housing overlaps the excitation coil and the reception coil printed on the stator printed circuit board in a vertical direction.
  • the permanent magnets are alternately and evenly distributed along the inner wall of the motor housing.
  • the number of pole pairs of the permanent magnetic steel is a positive integer greater than or equal to 1.
  • a rotor bearing is provided on the rotating shaft of the motor, and a stator bearing is provided on the stator chassis.
  • a spring is provided between the outer rotor and the stator.
  • the present invention differs from the traditional outer rotor direct drive motor in that it uses an electromagnetic induction position encoder.
  • the electromagnetic induction position encoder has The following advantages:
  • the receiving coil has one or more periodically repeating specific geometric structure features.
  • the more the number of repetitive cycles the more the number of signals obtained, the higher the resolution of the output signal, not only speed up the circuit processing Speed can improve the accuracy of the encoded signal.
  • increasing the number of receiving coil cycles only requires drawing more receiving coils on the stator printed circuit board, and does not add additional cost;
  • Figure 1 is a schematic diagram of the external rotor direct drive motor
  • Figure 2 is a cross-sectional view of the appearance of a conventional external rotor direct drive motor
  • Figure 3 is a schematic diagram of the explosion structure of a traditional external rotor direct drive motor
  • FIG. 4 is a schematic diagram of the outer rotor of a traditional outer rotor direct drive motor
  • FIG. 5 is a schematic diagram of a stator printed circuit board of a conventional external rotor direct drive motor
  • Example 7 is a schematic diagram of an explosion structure of Example 1 of the present invention.
  • Example 8 is a schematic diagram of an outer rotor of Example 1 of the present invention.
  • FIG. 9 is a schematic diagram of a printed circuit board of an example of the invention.
  • Example 10 is a schematic diagram of an explosion structure of Example 2 of the present invention.
  • FIG. 11 is a schematic diagram of the outer rotor of Example 2 of the present invention.
  • Figure 1 is a schematic diagram of the external rotor direct drive motor.
  • Fig. 2 is a cross-sectional view of a conventional external rotor direct drive motor.
  • Figure 3 is a schematic diagram of the explosion structure of a traditional external rotor direct drive motor.
  • the traditional outer rotor direct drive motor is composed of an outer rotor and a stator.
  • the outer rotor is installed outside the stator.
  • the outer rotor includes: a motor housing 1, a motor rotating shaft 2, a permanent magnetic steel 3 and a rotor
  • the bearing 4 wherein the motor housing 1 forms a storage space, wraps the stator winding 6 and the motor shaft 2 is directly connected to the motor housing 1 at the same time, and the permanent magnet 3 ( Or embedded in the inner wall of the motor casing), the rotor bearing 4 is installed on the motor shaft 2 and its role is to reduce the friction of the shaft 2 during rotation;
  • the stator includes: stator winding 6, stator printed circuit board 7, stator bearing 8 and stator chassis 9, wherein the stator winding 6 is installed on the stator printed circuit board 7, the stator printed circuit board 7 is installed on the stator chassis 9, and the stator bearing 8 is installed on the stator chassis 9, its role is also to reduce the rotation shaft 2 during the rotation process friction.
  • the spring 5 is
  • Fig. 4 is a schematic diagram of the outer rotor of a conventional outer rotor direct drive motor.
  • the outer rotor is composed of a motor housing 1, a motor rotating shaft 2, a permanent magnet 3 and a rotor bearing 4.
  • the permanent magnets 3 are evenly distributed along the inner surface of the motor casing 1 (or embedded in the inner wall of the motor casing), and the polarity is alternately distributed.
  • the number of pole pairs of the permanent magnet is an integer greater than or equal to 1 (in this example, the number of pole pairs is 10 ).
  • One end of the motor rotating shaft 2 is directly connected with the motor housing 1.
  • the rotor bearing 4 is installed on the rotating shaft 2 of the motor, and its function is to reduce the friction of the rotating shaft 2 during the rotation.
  • FIG. 5 is a schematic diagram of a stator printed circuit board of a conventional external rotor direct drive motor.
  • three Hall switch chips (10a, 10b, and 10c) are provided on the stator printed circuit board 7 of the conventional outer rotor direct-drive motor, and the three Hall switch chips are respectively welded with a phase difference of 120 degrees in the circumferential direction.
  • the stator printed circuit board 7 its power, ground and output signals are connected to the connector 12 through the stator printed circuit board 7, and at the same time, the three Hall switch chips (10a, 10b and 10c) and the permanent magnet 3 are Vertically on the same line.
  • the welding holes (11a, 11b, 11c, 11d, 11e, and 11f) are used to install the stator winding 6, and the welding holes (11d, 11e, and 11f) as the common end of the three-phase current of the stator winding 6 are connected to the stator printed circuit board 7 at Together, the welding holes (11a, 11b, and 11c) are connected to the connector 12 through the stator printed circuit board 7 as the terminals of the three-phase current of the stator winding 6.
  • the connector 12 is connected to the motor control system, and is used to output the UVW signal of the motor position and control the switching of the three-phase current.
  • the three Hall switch chips (10a, 10b, and 10c) sense the magnetic field generated by the permanent magnet 3 directly above, respectively generate U, V, and W switching signals, and transmit them to the motor control system to control the three-phase current. Switch, and finally control the start and stop of the motor.
  • the position encoder used in the external rotor direct-drive motor is a simple three Hall switches, the most basic role of which is to collect the position signal of the three-phase current switching of the motor, and the resolution of the position encoder is limited by the motor
  • the number of pole pairs for example, the number of pole pairs of the motor is 1, then the motor can only get 6 position signals in one rotation, and the resolution is much lower than that of the ordinary servo motor, so it cannot accurately reflect the position information of the motor rotation, making the control system ineffective Control the motor efficiency, speed and output torque and other parameters, and cause waste of energy. If you want to increase the resolution, you need to increase the number of motor pole pairs, which will greatly increase the cost.
  • the present invention has been improved based on the structure of the outer rotor direct drive motor, and an electromagnetic induction type position encoder is used to replace the Hall switch.
  • FIG. 6 is a cross-sectional view of an external appearance of an example of an external rotor direct drive motor of the present invention.
  • FIG. 7 is a schematic diagram of an explosion structure of an example of an outer rotor direct drive motor of the present invention.
  • an example of an outer rotor direct-drive motor of the present invention is composed of an outer rotor and a stator.
  • the outer rotor is installed outside the stator.
  • the outer rotor includes: a motor housing 1, a motor rotating shaft 2, a permanent magnet 3, and a rotor
  • the bearing 4 and the rotor printed circuit board 13 in which the motor housing 1 forms a storage space, wraps the stator winding 6 and the motor shaft 2 is directly connected to the motor housing 1 at one end, and at the same time, the inner wall side surface of the motor housing 1 is installed
  • the rotor printed circuit board 13 is installed on the bottom of the side wall of the motor casing 1
  • the rotor bearing 4 is installed on the motor rotating shaft 2, its role is to reduce the rotating shaft 2 during the rotation process Friction
  • stator includes: stator winding 6, stator printed circuit board 14, stator bearing 8 and stator chassis 9, wherein the stator winding 6
  • FIG. 8 is a schematic diagram of an outer rotor of an example of an outer rotor direct drive motor of the present invention.
  • the outer rotor is composed of a motor housing 1, a motor rotating shaft 2, a permanent magnet 3, a rotor bearing 4 and a rotor printed circuit board 13.
  • the permanent magnets 3 are evenly distributed along the inner surface of the motor casing 1 (or embedded in the inner wall of the motor casing), and the polarity is alternately distributed.
  • the number of pole pairs of the permanent magnet is an integer greater than or equal to 1 (in this example, the number of pole pairs is 10 ).
  • One end of the motor rotating shaft 2 is directly connected with the motor housing 1.
  • the rotor bearing 4 is installed on the rotating shaft 2 of the motor, and its function is to reduce the friction of the rotating shaft 2 during the rotation.
  • the rotor printed circuit board 13 is installed on the bottom of the side wall of the motor housing 1, and at the same time, the rotor printed circuit board 13 is printed with a plurality of periodically repeated scale areas of conductive material in the circumferential direction.
  • FIG. 9 is a schematic diagram of a stator printed circuit board of an example of an external rotor direct drive motor of the present invention.
  • the stator printed circuit board 14 is printed with excitation coils 15 and receiving coils 16 in the circumferential direction, respectively connected to the processing chip 17, and the power, ground and output signals of the processing chip are connected to the stator printed circuit board 14 to On the connector 12, at the same time, the exciting coil 15, the receiving coil 16 and the conductive material scale area on the rotor printed circuit board 13 overlap in the vertical direction.
  • the welding holes (11a, 11b, 11c, 11d, 11e, and 11f) are used to install the stator winding 6, and the welding holes (11d, 11e, and 11f) as the common end of the three-phase current of the stator winding 6 are connected to the stator printed circuit board 7 at Together, the welding holes (11a, 11b, and 11c) are connected to the connector 12 through the stator printed circuit board 7 as the terminals of the three-phase current of the stator winding 6.
  • the connector 12 is connected to the motor control system and used to output the motor position encoding signal and control the switching of the three-phase current.
  • the working mode is as follows:
  • the processing chip 17 cooperates with the excitation coil 15 to generate a high-frequency periodic AC voltage and current, and the alternating current flowing through the excitation coil will form an alternating electromagnetic field in its peripheral area.
  • the conductive material scale area on the rotor printed circuit board 13 is used to affect the coupling relationship between the excitation coil 15 and the receiving coil 16.
  • the motor housing 1 and the rotor printed circuit board 13 are rotated together, and the excitation coil 15
  • the alternating electromagnetic field causes an eddy current field in the conductive material scale area on the rotor printed circuit board 13, thereby weakening the alternating electromagnetic field strength of the excitation coil 15.
  • the uneven electromagnetic field strength changes the induced electromotive force on the receiving coil 16.
  • the structure of the first example of the outer rotor direct drive motor of the present invention has an additional rotor printed circuit board 13 compared with the structure of the traditional outer rotor direct drive motor. If considering the increase in cost and installation complexity, the present invention provides another outer rotor Direct drive motor structure.
  • FIG. 10 is a schematic diagram of an explosion structure of an example of an external rotor direct drive motor of the present invention.
  • Example 2 of the outer rotor direct drive motor of the present invention is composed of an outer rotor and a stator.
  • the outer rotor is installed outside the stator.
  • the outer rotor includes: a motor housing 1, a motor rotating shaft 2, a permanent magnet 3, and a rotor bearing 4.
  • the motor housing 1 forms a storage space, wraps the stator winding 6, the motor rotating shaft 2 is directly connected to the motor housing 1 at the same time, and the permanent magnet 3 (or embedded in the motor) is installed on the side surface of the inner wall of the motor housing 1
  • the stator includes: stator winding 6, stator printed circuit board 14, stator bearing 8 and stator chassis 9, wherein
  • the stator winding 6 is installed on the stator printed circuit board 14 (including at least the excitation coil 15 and the receiving coil 16), the stator printed circuit board 14 is installed on the stator chassis 9, and the stator bearing 8 is installed on the stator chassis 9, the role of which is also reduced The friction of the small rotating shaft 2 during the rotation.
  • the spring 5 is installed between the outer rotor and the stator. When the two are squeezed by external force, the spring 5 will play a role in buffering and restoring deformation.
  • FIG. 11 is a schematic diagram of an outer rotor of an example of an outer rotor direct drive motor of the present invention.
  • the outer rotor is composed of a motor casing 1, a motor rotating shaft 2, a permanent magnet 3 and a rotor bearing 4.
  • the permanent magnets 3 are evenly distributed along the side surface of the inner wall of the motor housing 1 (or embedded in the inner wall of the motor housing), and the polarities are alternately distributed.
  • the number of pole pairs of the permanent magnetic steel 3 is an integer greater than or equal to 1 (in this example, the number of pole pairs is 10).
  • One end of the motor rotating shaft 2 is directly connected with the motor housing 1.
  • the rotor bearing 4 is installed on the rotating shaft 2 of the motor, and its function is to reduce the friction of the rotating shaft 2 during the rotation.
  • the bottom of the side wall of the motor housing 1 has a periodically repeated sawtooth structure 18, and the bottom of the side wall of the motor housing 1 overlaps the excitation coil 15 and the receiving coil 16 on the stator printed circuit board 14 in the vertical direction.
  • the processing chip 17 cooperates with the excitation coil 15 to generate a high-frequency periodic AC voltage and current, and the alternating current flowing through the excitation coil will form an alternating electromagnetic field in its peripheral area.
  • the periodically repeated sawtooth structure at the bottom of the side wall of the motor housing 1 is used to affect the coupling relationship between the excitation coil 15 and the receiving coil 16.
  • the motor housing 1 is driven to rotate together, and the alternating electromagnetic field of the excitation coil 15 makes the motor
  • the serrated structure 18 on the bottom of the side wall of the housing 1 generates an eddy current field, thereby weakening the alternating electromagnetic field strength of the excitation coil 15.
  • the uneven electromagnetic field strength changes the induced electromotive force on the receiving coil 16.
  • the difference between the outer rotor direct drive motor of the present invention and the traditional outer rotor direct drive motor is the use of electromagnetic induction position encoders.
  • the electromagnetic induction position encoders have the following advantages over Hall switches, magnetic effect encoders and photoelectric encoders. :
  • the receiving coil has one or more periodically repeating specific geometric structure features.
  • increasing the number of receiving coil cycles only requires drawing more receiving coils on the stator printed circuit board, and does not add additional cost.

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  • Microelectronics & Electronic Packaging (AREA)

Abstract

本发明带有位置编码器的外转子直驱电机，包括外转子以及设置在外转子内的定子；其中定子包括：定子底盘；定子印刷电路板，定子印刷电路板设置在定子底盘的一侧，在定子印刷电路板至少印制有激励线圈和接收线圈；定子绕组，定子绕组设置在定子印刷电路板上；外转子改变激励线圈和接收线圈之间的耦合强度。本发明具有如下优点：灵活的安装方式，支持穿轴安装，无需占用太多电机本体空间；稳固的传感器结构，转子刻度区和感应线圈都印制在印刷电路板上，即使在转速过快的情况下也不会发生变形、碎裂的情况，同时，其非接触式感应方式不受油污、电磁等外界环境干扰；在不增加额外成本、不改变电机结构的情况增加电机编码器信号的分辨率。

Description

带有位置编码器的外转子直驱电机 技术领域
本发明涉及一种带有位置编码器的外转子直驱电机。
背景技术
在日常生活中会看到一些电机直接带动皮带轮工作，无需使用减速机去连接工作机与电机。这些电机在驱动负载时，需要经过传动装置(如传动皮带等)来进行驱动。然后，实际上还有一种电机可以省去传动装置，直接驱动负载，这种电机就是采用了“直接驱动技术”的直驱电机。我们都知道，传统电机的传动机构是电机动子通过电机轴再通过一系列的机械传动机构如联轴器、丝杆、同步带、齿条、减速机等等连接负载，在这个过程中，从机械角度上就已经增加了存在间隙、弹性变形、摩擦阻尼等等因素的可能性，从而造成设备刚性、响应特性的降低与损失。
与传统电机不同的是，直驱电机是将移动负载和电机动子直接耦合在一起，从而省去了诸如减速器、齿轮箱和皮带轮等连接机构，从而使整个系统具有高效低耗、高速、高可靠免维护、高刚度快响应、无需润滑、运行安静等优点。
同时，由于直驱电机输出力矩大，所以也被成为力矩电机。而为了使输出力矩最大化，一般采用外转子直驱电机的设计方式。外转子电机就是转子是外面的永磁体磁极，里面的线圈部分是固定不动的；内转子电机就是转子是里面的线圈部分，外面的永磁体磁极是固定不动的。在相同的电机尺寸下，外转子电机的输出扭矩要比内转子电机的输出扭矩要大的多，所以，为了使输出力矩最大化，许多设计人员一般采用外转子直驱电机的设计方式。
而在作为电机控制系统中最为重要一环的位置编码器选择上，外转子直驱电机在技术上存在很多壁垒：
1)目前很多伺服电机编码器采用磁效应编码器或者光电编码器，其中，磁效应编码器需要安装在电机轴端，而外转子直驱电机的电机轴一端与电机外壳相连接，另一端直接与移动负载相连接，没有剩余的空间用于磁效应编码器的安装；由于某些工作环境的恶劣，譬如振动、油污等都会造成光电编码器的损坏，加上价格昂贵， 光电编码器同样不是外转子直驱电机设计人员的首选；
2)目前市场上很多外转子直驱电机采用的位置编码器就是简单的三个霍尔开关，其最基本的作用就是作为电机三相电流切换的位置信号采集，而该位置编码器的分辨率受限于电机极对数，例如电机极对数为1，那电机旋转一周，只能得到6个位置信号，分辨率远远低于普通伺服电机，从而无法精确反应电机旋转的位置信息，使得控制系统无法有效地控制电机效率、速度和输出力矩等参数，并造成能源浪费。
发明内容
针对现有技术中的缺陷，本发明目的在于提供一种解决上述技术问题的带有位置编码器的外转子直驱电机。
为解决上述技术问题，本发明带有位置编码器的外转子直驱电机，包括外转子以及设置在所述外转子内的定子；其中所述定子包括：定子底盘；定子印刷电路板，所述定子印刷电路板设置在所述定子底盘的一侧，在所述定子印刷电路板至少印制有激励线圈和接收线圈；定子绕组，所述定子绕组设置在所述定子印刷电路板上；所述外转子改变所述激励线圈和所述接收线圈之间的耦合强度。
优选地，所述外转子包括：电机外壳；电机转轴，所述电机转轴的一端伸入所述电机外壳内、与所述电机外壳的底部连接；永久磁钢，所述永久磁钢设置在所述电机外壳的内侧壁上；感应机构，所述感应机构设置在所述电机外壳上，所述感应机构与所述激励线圈和所述接收线圈对应；其中所述感应机构改变所述激励线圈和所述接收线圈之间的耦合强度。
优选地，所述感应机构包括转子印刷电路板，所述转子印刷电路板设置在所述电机外壳上，在所述转子印刷电路板上印制有沿圆周方向上的多个周期性重复的导电材料刻度区。
优选地，所述转子印刷电路板上印制的所述导电材料刻度区在垂直方向上和所述定子印刷电路板上印制的所述激励线圈和所述接收线圈重叠。
优选地，所述感应机构包括锯齿结构，所述锯齿结构呈周期性重复，且设置在所述电机外壳侧壁的底部。
优选地，所述电机外壳侧壁底部的所述锯齿结构与所述定子印刷电路板上印制的所述激励线圈和所述接收线圈在垂直方向上重叠。
优选地，所述永久磁钢沿所述电机外壳的内壁极性交替均匀分布。
优选地，所述永久磁钢的极对数为大于等于1的正整数。
优选地，在所述电机转轴上设有转子轴承，在所述定子底盘上设有定子轴承。
优选地，在所述外转子与所述定子之间设有弹簧。
与现有技术相比，本发明相较传统外转子直驱电机不同的地方是采用电磁感应式位置编码器，电磁感应式位置编码器相较霍尔开关、磁效应编码器和光电编码器有如下优点：
a)灵活的安装方式，支持穿轴安装，无需占用太多电机本体空间；
b)稳固的传感器结构，转子刻度区和感应线圈都印制在印刷电路板上，即使在转速过快的情况下也不会发生变形、碎裂的情况，同时，其非接触式感应方式不受油污、电磁等外界环境干扰；
c)高精度高分辨率，接收线圈具有一个或多个周期性重复的特定几何图形结构特点，重复周期数越多，得到的信号数量越多，输出信号的分辨率越高，不仅加快电路处理速度，更可以提高编码信号的精度。不同于传统电机增加电机极对数来提高分辨率，本实例中，增加接收线圈周期数只需要定子印刷电路板上多绘制一些接收线圈，并不会增加额外的成本；
d)在不增加额外成本、不改变电机结构的情况增加电机编码器信号的分辨率。
附图说明
通过阅读参照以下附图对非限制性实施例所作的详细描述，本发明的其它特征目的和优点将会变得更明显。
图1为外转子直驱电机外观示意图；
图2为传统外转子直驱电机外观剖面图；
图3为传统外转子直驱电机爆炸结构示意图；
图4为传统外转子直驱电机外转子示意图；
图5为传统外转子直驱电机定子印刷电路板示意图；
图6为本发明实例一剖面图
图7为本发明实例一爆炸结构示意图；
图8为本发明实例一外转子示意图；
图9为本发明实例一定子印刷电路板示意图；
图10为本发明实例二爆炸结构示意图；
图11为本发明实例二外转子示意图。
具体实施方式
下面结合具体实施例对本发明进行详细说明。以下实施例将有助于本领域的技术人员进一步理解本发明，但不以任何形式限制本发明。应当指出的是，对本领域的普通技术人员来说，在不脱离本发明构思的前提下，还可以做出若干变化和改进。
图1为外转子直驱电机外观示意图。
图2为传统外转子直驱电机外观剖面图。
图3为传统外转子直驱电机爆炸结构示意图。
如图1、图2和图3所示，传统外转子直驱电机由外转子与定子组成，外转子安装在定子外面，外转子包括：电机外壳1、电机转轴2、永久磁钢3和转子轴承4，其中，电机外壳1形成储物空间，将定子绕组6包裹在内，电机转轴2一端与电机外壳1直接连接在一起，同时，电机外壳1的内壁侧表面安装有永久磁钢3(或嵌入电机外壳内壁)，转子轴承4安装在电机转轴2上，其作用是减小转轴2在转动过程中的摩擦；定子包括：定子绕组6、定子印刷电路板7、定子轴承8和定子底盘9，其中，定子绕组6安装在定子印刷电路板7上，定子印刷电路板7安装在定子底盘9上，定子轴承8安装在定子底盘9上，其作用也是减小转轴2在转动过程中的摩擦。弹簧5安装在外转子与定子之间，当两者受到外力发生挤压等情况，弹簧5会起到缓冲和恢复形变的作用。
图4为传统外转子直驱电机外转子示意图。
如图4所示，外转子由电机外壳1、电机转轴2、永久磁钢3和转子轴承4构成。永久磁钢3沿电机外壳1的内壁侧表面(或嵌入电机外壳内壁)均匀分布，极性交替分布，永久磁钢的极对数为大于等于1的整数(本实例中，极对数为10)。电机转轴2一端与电机外壳1直接连接在一起。转子轴承4安装在电机转轴2上，其作用是减小转轴2在转动过程中的摩擦。
图5为传统外转子直驱电机定子印刷电路板示意图。
如图5所示，传统外转子直驱电机的定子印刷电路板7上设置有三颗霍尔开关芯片(10a、10b和10c)，三颗霍尔开关芯片分别沿圆周方向相距120度相位差焊接在定子印刷电路板7上，其电源、地及输出信号通过定子印刷电路板7连接到接插件12上，同时，这三颗霍尔开关芯片(10a、10b和10c)与永久磁钢3在垂直方向上在同一直线 上。焊接孔(11a、11b、11c、11d、11e和11f)用于安装定子绕组6，焊接孔(11d、11e和11f)作为定子绕组6三相电流的公共端在定子印刷电路板7上连接在一起，焊接孔(11a、11b和11c)作为定子绕组6三相电流的引出端通过定子印刷电路板7连接到接插件12上。接插件12连接到电机控制系统中，用于输出电机位置UVW信号并控制三相电流的切换。
基于上述传统外转子直驱电机结构，其工作方式如下：
系统供电后，三颗霍尔开关芯片(10a、10b和10c)感应正上方永久磁钢3产生的磁场，分别产生U、V和W开关信号，并传输到电机控制系统来控制三相电流的切换，最终控制电机的启动和停止。
但是基于上述结构的外转子直驱电机存在如下问题：
1)外转子直驱电机采用的位置编码器就是简单的三个霍尔开关，其最基本的作用就是作为电机三相电流切换的位置信号采集，而该位置编码器的分辨率受限于电机极对数，例如电机极对数为1，那电机旋转一周，只能得到6个位置信号，分辨率远远低于普通伺服电机，从而无法精确反应电机旋转的位置信息，使得控制系统无法有效地控制电机效率、速度和输出力矩等参数，并造成能源浪费。如果要提高分辨率，就要增加电机极对数，又会使成本大大增加。
2)目前很多伺服电机编码器采用磁效应编码器或者光电编码器，其中，磁效应编码器需要安装在电机轴端，而外转子直驱电机的电机轴一端与电机外壳相连接，另一端直接与移动负载相连接，没有剩余的空间用于磁效应编码器的安装；由于某些工作环境的恶劣，譬如振动、油污等都会造成光电编码器的损坏，加上价格昂贵，光电编码器同样不是外转子直驱电机设计人员的首选。
为了解决上述问题，本发明基于上述外转子直驱电机结构进行了改进，采用电磁感应式位置编码器替换霍尔开关。
图6为本发明外转子直驱电机实例一外观剖面图。
图7为本发明外转子直驱电机实例一爆炸结构示意图。
如图6和图7所示，本发明外转子直驱电机实例一由外转子与定子组成，外转子安装在定子外面，外转子包括：电机外壳1、电机转轴2、永久磁钢3、转子轴承4和转子印刷电路板13，其中，电机外壳1形成储物空间，将定子绕组6包裹在内，电机转轴2一端与电机外壳1直接连接在一起，同时，电机外壳1的内壁侧表面安装有永久磁钢3(或嵌入电机外壳内壁)，转子印刷电路板13安装在电机外壳1侧壁底部上，转子轴 承4安装在电机转轴2上，其作用是减小转轴2在转动过程中的摩擦；定子包括：定子绕组6、定子印刷电路板14、定子轴承8和定子底盘9，其中，定子绕组6安装在定子印刷电路板14(至少包括激励线圈15及接收线圈16)上，定子印刷电路板14安装在定子底盘9上，定子轴承8安装在定子底盘9上，其作用也是减小转轴2在转动过程中的摩擦。弹簧5安装在外转子与定子之间，当两者受到外力发生挤压等情况，弹簧5会起到缓冲和恢复形变的作用。
图8为本发明外转子直驱电机实例一外转子示意图；
如图8所示，外转子由电机外壳1、电机转轴2、永久磁钢3、转子轴承4和转子印刷电路板13构成。永久磁钢3沿电机外壳1的内壁侧表面(或嵌入电机外壳内壁)均匀分布，极性交替分布，永久磁钢的极对数为大于等于1的整数(本实例中，极对数为10)。电机转轴2一端与电机外壳1直接连接在一起。转子轴承4安装在电机转轴2上，其作用是减小转轴2在转动过程中的摩擦。转子印刷电路板13安装在电机外壳1侧壁底部上，同时，转子印刷电路板13沿圆周方向上印制有多个周期性重复的导电材料刻度区。
图9为本发明外转子直驱电机实例一定子印刷电路板示意图。
如图9所示，定子印刷电路板14沿圆周方向印制有激励线圈15及接收线圈16，分别接入处理芯片17，该处理芯片的电源、地及输出信号通过定子印刷电路板14连接到接插件12上，同时，激励线圈15、接收线圈16与转子印刷电路板13上的导电材料刻度区在垂直方向上重叠。焊接孔(11a、11b、11c、11d、11e和11f)用于安装定子绕组6，焊接孔(11d、11e和11f)作为定子绕组6三相电流的公共端在定子印刷电路板7上连接在一起，焊接孔(11a、11b和11c)作为定子绕组6三相电流的引出端通过定子印刷电路板7连接到接插件12上。接插件12连接到电机控制系统中，用于输出电机位置编码信号并控制三相电流的切换。
基于上述本发明外转子直驱电机实例一结构，其工作方式如下：
系统供电后，处理芯片17配合激励线圈15产生高频周期性交流电压和电流，流过激励线圈的交变电流将在其周边区域内形成交变电磁场。
根据法拉第电磁感应定律可知，通过闭合线圈的磁通量发生变化，会在闭合线圈上产生感应电动势。当激励线圈上产生的交变电磁场穿过闭合接收线圈组件时，由于通过闭合接收线圈组件的磁通量发生交变，在每个扇环形线圈上产生频率相同的交变感应电动势。
转子印刷电路板13上的导电材料刻度区用于影响激励线圈15和接收线圈16之间的耦合关系，当外转子转动时，带动电机外壳1及转子印刷电路板13一起旋转，激励线圈15的交变电磁场使得转子印刷电路板13上的导电材料刻度区产生涡流场，从而削弱激励线圈15的交变电磁场强度。不均匀的电磁场强度将接收线圈16上的感应电动势发生变化。当转子印刷电路板13相对定子印刷电路板14旋转一圈后，在接收线圈16上分别得到多个周期的接收信号；接收信号输入处理芯片17后，经过计算输出高精度高分辨率的编码信号，并传输到电机控制系统，从而精准地控制电机启停、速度控制及功率密度监控等。
本发明外转子直驱电机实例一中结构，相较传统外转子直驱电机结构，多了一个转子印刷电路板13，如果考虑到成本的增加及安装复杂性，本发明提供另一种外转子直驱电机结构。
图10为本发明外转子直驱电机实例二爆炸结构示意图。
如图10所示，本发明外转子直驱电机实例二由外转子与定子组成，外转子安装在定子外面，外转子包括：电机外壳1、电机转轴2、永久磁钢3、转子轴承4，其中，电机外壳1形成储物空间，将定子绕组6包裹在内，电机转轴2一端与电机外壳1直接连接在一起，同时，电机外壳1的内壁侧表面安装有永久磁钢3(或嵌入电机外壳内壁)，转子轴承4安装在电机转轴2上，其作用是减小转轴2在转动过程中的摩擦；定子包括：定子绕组6、定子印刷电路板14、定子轴承8和定子底盘9，其中，定子绕组6安装在定子印刷电路板14(至少包括激励线圈15及接收线圈16)上，定子印刷电路板14安装在定子底盘9上，定子轴承8安装在定子底盘9上，其作用也是减小转轴2在转动过程中的摩擦。弹簧5安装在外转子与定子之间，当两者受到外力发生挤压等情况，弹簧5会起到缓冲和恢复形变的作用。
图11为本发明外转子直驱电机实例二外转子示意图。
如图11所示，外转子由电机外壳1、电机转轴2、永久磁钢3、转子轴承4构成。永久磁钢3沿电机外壳1的内壁侧表面(或嵌入电机外壳内壁)均匀分布，极性交替分布，永久磁钢3的极对数为大于等于1的整数(本实例中，极对数为10)。电机转轴2一端与电机外壳1直接连接在一起。转子轴承4安装在电机转轴2上，其作用是减小转轴2在转动过程中的摩擦。电机外壳1侧壁底部呈周期性重复的锯齿结构18，且电机外壳1侧壁底部与定子印刷电路板14上的激励线圈15和接收线圈16在垂直方向上重叠。
基于上述本发明外转子直驱电机实例二结构，其工作方式如下：
系统供电后，处理芯片17配合激励线圈15产生高频周期性交流电压和电流，流过激励线圈的交变电流将在其周边区域内形成交变电磁场。
根据法拉第电磁感应定律可知，通过闭合线圈的磁通量发生变化，会在闭合线圈上产生感应电动势。当激励线圈上产生的交变电磁场穿过闭合接收线圈组件时，由于通过闭合接收线圈组件的磁通量发生交变，在每个扇环形线圈上产生频率相同的交变感应电动势。
电机外壳1侧壁底部周期性重复的锯齿结构用于影响激励线圈15和接收线圈16之间的耦合关系，当外转子转动时，带动电机外壳1一起旋转，激励线圈15的交变电磁场使得电机外壳1侧壁底部上的锯齿结构18产生涡流场，从而削弱激励线圈15的交变电磁场强度。不均匀的电磁场强度将接收线圈16上的感应电动势发生变化。当电机外壳1相对定子印刷电路板14旋转一圈后，在接收线圈16上分别得到多个周期的接收信号；接收信号输入处理芯片17后，经过计算输出高精度高分辨率的编码信号，并传输到电机控制系统，从而精准地控制电机启停、速度控制及功率密度监控等。
本发明外转子直驱电机相较传统外转子直驱电机不同的地方是采用电磁感应式位置编码器，电磁感应式位置编码器相较霍尔开关、磁效应编码器和光电编码器有如下优点：
a)灵活的安装方式，支持穿轴安装，无需占用太多电机本体空间；
b)稳固的传感器结构，转子刻度区和感应线圈都印制在印刷电路板上，即使在转速过快的情况下也不会发生变形、碎裂的情况，同时，其非接触式感应方式不受油污、电磁等外界环境干扰
c)高精度高分辨率，接收线圈具有一个或多个周期性重复的特定几何图形结构特点，重复周期数越多，得到的信号数量越多，输出信号的分辨率越高，不仅加快电路处理速度，更可以提高编码信号的精度。不同于传统电机增加电机极对数来提高分辨率，本实例中，增加接收线圈周期数只需要定子印刷电路板上多绘制一些接收线圈，并不会增加额外的成本。
d)在不增加额外成本、不改变电机结构的情况增加电机编码器信号的分辨率。
以上对本发明的具体实施例进行了描述。需要理解的是，本发明并不局限于上述特定实施方式，本领域技术人员可以在权利要求的范围内做出各种变化或修改，这并不影响本发明的实质内容。在不冲突的情况下，本申请的实施例和实施例中的特征可以任意 相互组合。

Claims (10)

  1. 一种带有位置编码器的外转子直驱电机，其特征在于，包括外转子以及设置在所述外转子内的定子；其中
    所述定子包括：
    定子底盘；
    定子印刷电路板，所述定子印刷电路板设置在所述定子底盘的一侧，在所述定子印刷电路板至少印制有激励线圈和接收线圈；
    定子绕组，所述定子绕组设置在所述定子印刷电路板上；
    所述外转子改变所述激励线圈和所述接收线圈之间的耦合强度。
  2. 根据权利要求1所述的带有位置编码器的外转子直驱电机，其特征在于，所述外转子包括：
    电机外壳；
    电机转轴，所述电机转轴的一端伸入所述电机外壳内、与所述电机外壳的底部连接；
    永久磁钢，所述永久磁钢设置在所述电机外壳的内侧壁上；
    感应机构，所述感应机构设置在所述电机外壳上，所述感应机构与所述激励线圈和所述接收线圈对应；其中
    所述感应机构改变所述激励线圈和所述接收线圈之间的耦合强度。
  3. 根据权利要求2所述的带有位置编码器的外转子直驱电机，其特征在于，所述感应机构包括转子印刷电路板，所述转子印刷电路板设置在所述电机外壳上，在所述转子印刷电路板上印制有沿圆周方向上的多个周期性重复的导电材料刻度区。
  4. 根据权利要求3所述的带有位置编码器的外转子直驱电机，其特征在于，所述转子印刷电路板上印制的所述导电材料刻度区在垂直方向上和所述定子印刷电路板上印制的所述激励线圈和所述接收线圈重叠。
  5. 根据权利要求2所述的带有位置编码器的外转子直驱电机，其特征在于，所述感应机构包括锯齿结构，所述锯齿结构呈周期性重复，且设置在所述电机外壳侧壁的底部。
  6. 根据权利要求5所述的带有位置编码器的外转子直驱电机，其特征在于，所述电机外壳侧壁底部的所述锯齿结构与所述定子印刷电路板上印制的所述激励线圈和所述接收线圈在垂直方向上重叠。
  7. 根据权利要求2所述的带有位置编码器的外转子直驱电机，其特征在于，所述永久磁钢沿所述电机外壳的内壁极性交替均匀分布。
  8. 根据权利要求7所述的带有位置编码器的外转子直驱电机，其特征在于，所述永久磁钢的极对数为大于等于1的正整数。
  9. 根据权利要求7所述的带有位置编码器的外转子直驱电机，其特征在于，在所述电机转轴上设有转子轴承，在所述定子底盘上设有定子轴承。
  10. 根据权利要求1所述的带有位置编码器的外转子直驱电机，其特征在于，在所述外转子与所述定子之间设有弹簧。
PCT/CN2020/080245 2019-11-27 2020-03-19 带有位置编码器的外转子直驱电机 WO2020114527A2 (zh)

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