WO2023020601A1 - Moteur sans balais à aimant permanent et son procédé de fabrication, actionneur d'articulation et robot - Google Patents

Moteur sans balais à aimant permanent et son procédé de fabrication, actionneur d'articulation et robot Download PDF

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Publication number
WO2023020601A1
WO2023020601A1 PCT/CN2022/113466 CN2022113466W WO2023020601A1 WO 2023020601 A1 WO2023020601 A1 WO 2023020601A1 CN 2022113466 W CN2022113466 W CN 2022113466W WO 2023020601 A1 WO2023020601 A1 WO 2023020601A1
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WO
WIPO (PCT)
Prior art keywords
stator
permanent magnet
winding
brushless motor
motor
Prior art date
Application number
PCT/CN2022/113466
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English (en)
Chinese (zh)
Inventor
潘韫哲
Original Assignee
上海舞肌科技有限公司
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Publication date
Priority claimed from CN202110956434.9A external-priority patent/CN115714479A/zh
Application filed by 上海舞肌科技有限公司 filed Critical 上海舞肌科技有限公司
Publication of WO2023020601A1 publication Critical patent/WO2023020601A1/fr

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12—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
    • 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
    • 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
    • H02K1/28—Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures
    • H02K1/30—Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures using intermediate parts, e.g. spiders
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/06—Embedding prefabricated windings in machines
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K21/00—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets
    • H02K21/12—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets
    • H02K21/14—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets rotating within the armatures
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/28—Layout of windings or of connections between windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/32—Windings characterised by the shape, form or construction of the insulation
    • H02K3/34—Windings characterised by the shape, form or construction of the insulation between conductors or between conductor and core, e.g. slot insulation

Definitions

  • At least one embodiment of the present disclosure relates to a permanent magnet brushless motor and a manufacturing method thereof, a robot joint actuator, a servo servo actuator, and a robot.
  • Embodiments of the present disclosure provide a permanent magnet brushless motor and its manufacturing method, a robot joint actuator, a servo steering gear actuator, and a robot, which can significantly improve the slot full rate of the motor, the motor constant per unit mass of the motor, and the output power Density, suitable for small motors, and can realize high-volume, low-cost manufacturing of motors.
  • an embodiment of the present disclosure provides a permanent magnet brushless motor, the motor is a fractional slot rotor motor, the motor includes a stator and a rotor; the stator includes a stator core and a stator winding, and the stator The winding is a non-staggered concentrated winding with a span of 1; the rotor includes a permanent magnet and a permanent magnet carrier, and the permanent magnet is arranged outside the permanent magnet carrier, wherein the permanent magnet is used for excitation to generate a rotating magnetic field, so
  • the stator core includes a stator yoke and a stator tooth, the stator tooth includes a plurality of stator teeth arranged on the stator yoke, and an insulating layer is provided on the surface of each stator tooth; the stator winding includes a machine A plurality of winding coils formed by winding, each of the plurality of winding coils is symmetrically arranged on the corresponding stator tooth with the radial central axis corresponding to
  • each of the winding coils includes multi-layer wires from the inside to the outside, the number of layers of the multi-layer wires is n layers, and the incoming wires of the winding coils are on the side close to the stator yoke, wherein n is an integer greater than zero, and when n is an odd number, the number of turns of the outermost wire is less than or equal to 90% of the average number of turns of other inner layer wires.
  • the wire of each said winding coil is a round wire with a circular cross section or a square wire with an approximately square cross section, the outer diameter of the strip of the round wire is dc, and the side length of the strip of the square wire is dc ,in
  • in or p is 1/2 of the arc length between adjacent stator teeth in the axial section of the stator core and the tooth ends away from the stator yoke
  • q is the axial section of the stator core 1/2 of the arc length between the tooth roots of adjacent stator teeth close to the stator yoke.
  • stator teeth have the same width from a tooth end far away from the stator yoke to a tooth root close to the stator yoke; or from a tooth end far away from the stator yoke to a tooth root close to the stator At the root of the yoke, the width of the stator teeth gradually increases.
  • the surface insulation layer of each stator tooth is an electrophoretic surface treatment layer or a vapor deposition surface treatment layer.
  • edges of the stator teeth extending from the tooth root to the tooth end are chamfered.
  • the width of the narrowest part of the stator teeth is greater than or equal to 30% of the inner circumference length/N of the inner diameter of the stator, and less than or equal to 60% of the inner circumference length/N of the inner diameter of the stator, wherein , N is the number of teeth of the stator teeth.
  • the width at the widest point of the stator teeth is less than or equal to 3.4 mm.
  • the thickness of the stator yoke is greater than or equal to 60% of the width of the stator teeth at the narrowest point, and less than or equal to 200% of the width of the stator teeth at the narrowest point.
  • an air gap is formed between the stator and the rotor, and the average air gap distance of the motor is less than or equal to 0.5% of the outer diameter of the stator.
  • the outer diameter of the stator core is less than or equal to 150mm.
  • the axial height of the stator core is less than or equal to 25% of the outer diameter of the stator core.
  • the average radial thickness of the permanent magnet is less than or equal to 25 times the average air gap distance and greater than or equal to 5 times the average air gap distance.
  • the inner diameter of the stator core is greater than or equal to 77.5% of the outer diameter of the stator core and less than or equal to 90% of the outer diameter of the stator core.
  • the permanent magnet carrier includes a cavity, and the diameter of the cavity is greater than or equal to 57.5% of the outer diameter of the stator core.
  • the motor is a three-phase motor
  • the greatest common divisor C of the number of teeth of the stator teeth/3 and the number of magnetic poles of the permanent magnet is greater than or equal to 2 and less than or equal to 8
  • the number of teeth of the stator teeth/C/ The three winding coils are connected in series to form a minimum unit, and the minimum units are connected in series, in parallel or mixed in series and parallel to form the stator winding of any phase.
  • the ratio of the number of magnetic poles of the permanent magnet to the number of teeth of the stator is greater than or equal to 0.78 and less than or equal to 1.34.
  • the permanent magnet is composed of several permanent magnet blocks, the several permanent magnets form a Halbach array, and the permanent magnet carrier is made of non-soft magnetic material.
  • the embodiments of the present disclosure also provide a method for manufacturing the above-mentioned permanent magnet brushless motor, including: preparing the stator core; preparing the winding coil of the stator winding, including: using a winding machine to wind the enameled wire
  • the air-core coil is obtained after being wound on the skeleton; the air-core coil is sheathed and fixed on the stator core; the electrical connection of the coil includes: connecting the winding coil.
  • embodiments of the present disclosure further provide a robot joint actuator, including the permanent magnet brushless motor described in any of the first aspects.
  • embodiments of the present disclosure further provide a servo steering gear actuator, including the brushless permanent magnet motor described in any of the first aspects.
  • embodiments of the present disclosure further provide a robot, including the actuator as described in the third aspect or the fourth aspect.
  • Embodiments of the present disclosure provide a permanent magnet brushless motor and its manufacturing method, a robot joint actuator, a servo servo actuator, and a robot. On the teeth, thereby avoiding the interference when the coil is wound, and improving the slot fullness rate.
  • the wire of the winding coil is determined
  • the outer diameter of the skin or the value range of the side length so as to determine the size of the wire used in the winding coil according to the stator core, etc., so that the motor obtained by winding such a wire can significantly improve the slot fill rate and improve the motor. Torque density and motor constant per unit mass.
  • the determination of the outer diameter or side length of the above-mentioned wires is coordinated with other motor structural parameters, such as the width of the narrowest part of the stator teeth, the average air gap distance, the outer diameter and inner diameter of the stator, and the motor manufacturing process. , thereby optimizing the size and structure of the motor, making the wound coils consistent, compact, and safe, ensuring the stable assembly of the coil and the motor and maximizing the use of the space of the motor slot, while ensuring low cogging torque and the motor While running smoothly, the motors produced in large quantities have a high slot full rate and low DC and AC copper losses, thereby improving the torque density of the motor and the motor constant per unit mass.
  • FIG. 1 is a schematic structural diagram of a permanent magnet brushless motor provided by an embodiment of the present disclosure
  • FIG. 2 is a schematic structural diagram of a permanent magnet brushless motor stator provided by an embodiment of the present disclosure
  • Fig. 3 is another structural schematic diagram of the permanent magnet brushless motor stator provided by the embodiment of the present disclosure.
  • FIG. 4A is a top view of a winding coil provided by an embodiment of the present disclosure.
  • Fig. 4B is a cross-sectional view of the winding coil provided by the embodiment of the present disclosure along line A-A;
  • FIG. 4C is an overall view of the winding coil provided by the embodiment of the present disclosure.
  • FIG. 5 is a schematic diagram of the simulation effect of the width of the narrowest part of the stator tooth/(the inner circumference of the stator where the inner diameter of the stator is located/the number of teeth) and the motor constant per unit weight of the motor according to an embodiment of the disclosure;
  • FIG. 6 is a schematic diagram of the simulation effect of the thickness of the stator yoke/the width of the narrowest part of the stator teeth and the motor constant per unit weight of the motor according to the embodiment of the disclosure;
  • FIG. 7 is a schematic diagram of the simulation effect of the ratio of the average air gap distance to the outer diameter of the stator and the motor constant per unit weight of the motor according to an embodiment of the disclosure
  • FIG. 8 is a schematic diagram of the simulation effect of the ratio of the average radial thickness of the permanent magnet of the motor to the average air gap distance and the motor constant per unit weight of the embodiment of the present disclosure
  • FIG. 9 is a schematic diagram of the simulation effect of the ratio of the axial height h of the stator core of the motor to the outer diameter of the stator core and the motor constant per unit weight of the motor according to an embodiment of the disclosure;
  • Fig. 10 is a schematic diagram of the simulation effect of the ratio of the inner diameter to the outer diameter of the stator core and the motor constant per unit weight of the motor according to the embodiment of the present disclosure
  • FIG. 11 is a schematic diagram of the relationship between the slot fullness ratio of the motor and the outer diameter of the belt or the side length dc of the belt according to an embodiment of the present disclosure.
  • FIG. 12 is a flow chart of a manufacturing method of a motor according to an embodiment of the present disclosure.
  • the performance of the robot motor can be measured by the motor constant density, that is, the motor constant per unit mass, that is, the motor constant/the weight of the motor.
  • the motor constants are defined as follows:
  • a small motor for a robot generally adopts stator teeth with boots to ensure low cogging torque and smooth operation of the motor.
  • the stator teeth with boots limit the selection of the winding process, so that the existing winding coils are usually directly wound on the stator teeth by a dedicated winding machine. This processing method severely limits the fullness of the stator slot of the motor.
  • a kind of robot motor generally uses a high-speed and low-torque motor design with a high reduction ratio to achieve high torque output, and there is still a big gap in improving the performance of the actuator by increasing the torque.
  • an embodiment of the present disclosure provides a permanent magnet brushless motor 100, the motor 100 is a fractional slot inner rotor motor, and the motor includes a stator 1 and a rotor 2;
  • the stator 1 includes a stator core 10 and a stator winding, the stator winding is a non-staggered concentrated winding with a span of 1;
  • the rotor 2 includes a permanent magnet 21 and a permanent magnet carrier 20, wherein the permanent magnet 21 is arranged on the Outside the permanent magnet carrier 20, the permanent magnet 21 is used for excitation to generate a rotating magnetic field.
  • the stator core 10 includes a stator yoke 101 and a stator tooth.
  • a plurality of stator teeth 102 the surface of each stator tooth 102 is provided with a surface insulation layer; the stator winding includes a plurality of winding coils 11 formed by machine winding, each of the plurality of winding coils 11 is formed in a corresponding The radial central axis 103 of the stator teeth 102 is symmetrically arranged on the corresponding stator teeth 102 as an axis of symmetry.
  • each stator tooth 102 is sheathed with a winding coil 11 .
  • two winding coils are sheathed on each stator tooth 102 .
  • more than two winding coils may be provided on each stator tooth.
  • the surface insulation layer provided on the surface of each stator tooth 102 can ensure the insulation of the stator winding and the stator core, and avoid electric leakage.
  • the surface insulating layer may be an electrophoretic surface treatment layer, that is, an electrophoretic surface treatment layer is formed on the surface of each stator tooth by electrophoretic treatment as a surface insulating layer. Electrophoretic (electro-coating or E-coating) surface treatment is also called electrophoretic coating treatment.
  • the surface insulating layer may be a vapor deposition surface treatment layer. Vapor deposition surface treatment refers to the process of forming a coating on the surface of a workpiece with gaseous substances.
  • Vapor deposition can be divided into physical vapor deposition and chemical vapor deposition.
  • the present disclosure does not limit the method and type of vapor deposition.
  • the surface insulating layer has both electrophoretic and vapor deposition surface treatments.
  • Vapor deposition surface or electrophoretic surface treatment is stable, with good consistency and adhesion, good pressure resistance, and a thin coating layer, which can reserve more space for copper wires and greatly improve the motor slot full rate.
  • the winding coil 11 can be sleeved and installed on the stator teeth 102 after being machined and formed.
  • the winding coil 11 processed by the machine can be isolated, that is, each coil has two disconnected lead wires, or it can be several winding coils directly connected by the machine.
  • connection of the winding coils to the winding coils can be completed by soldering on the printed circuit board, or by soldering wires in the air.
  • Embodiments of the present disclosure do not limit the manner of connecting the winding coils to the winding coils.
  • the coils wound by the machine are neatly arranged and have a high filling rate, which can further increase the torque density of the motor, the motor constant and the output power density of the motor, and improve the performance of the motor.
  • the winding coils close to the stator yoke can be sleeved on each stator tooth first, and then the winding coils far away from the stator yoke can be sleeved, so that each stator tooth
  • the winding coils when the winding coils are installed near the stator teeth of the stator yoke, interference with the winding coils already set on the adjacent stator teeth can be avoided, thereby improving the slot fill rate and further improving Motor constant and output power density of the motor. For robots, such high-performance motors can further improve device performance.
  • the width of the stator teeth 102 is the same everywhere, so as to facilitate corresponding winding coils. 11, and can improve space utilization, thereby increasing the motor constant per unit weight. It can be understood that, in some examples, from the tooth end 1021 far away from the stator yoke 101 to the tooth root 1022 close to the stator yoke 101 , the width of the stator teeth can also gradually increase.
  • the stator teeth generally have a T-shaped structure (that is, the stator teeth have a boot structure), and the stator teeth with boots will affect the size of the cavity of the winding coil, thereby reducing the The space utilization of the winding coil is improved.
  • the stator teeth are not formed with boots, and the removal of the boots improves the space utilization of the winding coils, which is beneficial to further increase the motor constant per unit weight and improve the performance of the motor.
  • the stator core 10 may be a one-piece core.
  • the integrated iron core is different from a plurality of modules or partially assembled iron cores, and an iron core formed by stacking integral punched sheets also belongs to the integrated iron core referred to in the embodiments of the present disclosure.
  • the stator core 10 may be formed by laminating silicon steel sheets or soft magnetic material sheets.
  • the one-piece iron core is easy to process, with mature technology and low cost.
  • the edge 1023 of the stator tooth 102 extending from the tooth end to the tooth root is chamfered.
  • the edges of the stator teeth 102 extending from the tooth root portion 1022 to the tooth end portion 1021 are formed to have a chamfered structure.
  • the tooth end edges and/or the tooth roots of the stator teeth 102 are also chamfered. Due to the limitation of the mechanical properties of the material, the inner wall of the winding coil cannot be made into a perfect right angle, and a certain rounded corner will be formed.
  • the chamfered stator teeth 102 can adapt to the fillet of the inner wall of the coil, reduce unnecessary copper in the motor, and improve the operating efficiency of the motor.
  • the chamfered structure is a structure formed by processing a sharp edge into a blunt edge, and the blunt edge after the chamfering treatment can be an obtuse edge, a circular arc edge or other The edge is not sharp, which is not limited by the embodiments of the present disclosure.
  • the stator 1 may further include an adhesive layer; the winding coil 11 is fixed to the stator tooth 102 through the adhesive layer.
  • the adhesive layer may be formed after the glue evenly coated on the surface of the stator tooth 102 or the inner surface of the winding coil 11 is cured.
  • glue can be evenly coated on part or all of the surface of the stator tooth 102, and then the winding coil 11 is placed on the stator tooth 102, and an adhesive layer is formed after the glue is cured, so that the winding coil 11 and the stator tooth 102 are fixed together, Not easy to loose.
  • the adhesive layer can be formed after the glue applied on and covering the axial surface of the winding coil 11 installed on the stator tooth 102 is cured, so as to fix the opposite sides of the winding coil 11 and the winding coil 11. The position is such that the winding coil 11 is fixed on the stator tooth 102 without loosening.
  • the present disclosure does not limit the specific implementation forms and methods of the adhesive layer.
  • the size and structure of the motor are also designed, so that the performance of the motor can be improved, the production feasibility of the motor can be improved, and an excellent motor constant per unit weight can be obtained.
  • motor dimensions and construction are as follows:
  • the width of the stator teeth 102 is w, the diameter of the inner circle of the stator core 10, that is, the inner diameter is d1, and the inner diameter of the stator core 10 is The inner circumference, that is, the inner diameter of the stator 1 is d1 ⁇ , which is denoted as p1.
  • the width of the narrowest part of the stator teeth 102 may be greater than or equal to 30% of the inner circumference p1/N of the inner diameter of the stator, and may be less than or equal to 60% of the inner circumference p1/N of the inner diameter of the stator, where N is The number of stator teeth 102 .
  • N can be 48.
  • the width of the narrowest part of the stator tooth 102 is the width of the stator tooth 102, and for the motor whose width of the stator tooth 102 is not the same everywhere, The width of the narrowest part of the stator teeth 102 is the minimum width of the stator teeth.
  • the number of stator teeth 102 may be forty-eight.
  • Fig. 5 shows that when the number of teeth N of the stator teeth 102 is 48, the simulation effect schematic diagram of the width of the narrowest part of the stator teeth/(the inner circumference of the inner diameter of the stator/the number of teeth) and the motor constant per unit weight, as shown in Fig. 5 Indicates that when the width of the narrowest part of the stator teeth 102 is greater than or equal to 30% of the inner circumference p1/N of the inner diameter of the stator and less than or equal to 60% of the inner circumference p1/N of the inner diameter of the stator, the unit weight
  • the motor constant is in approx. to appointment
  • the motor of the embodiment of the present disclosure having the above structure significantly improves the motor constant of the motor per unit weight, and improves the output efficiency of the motor.
  • the thickness of the stator yoke 101 is L, and the thickness L can be set to be greater than or equal to 60% of the width of the narrowest part of the stator teeth, and less than or equal to the width of the stator teeth. 200% of the width w at the narrowest point of the tooth.
  • FIG. 6 shows a schematic diagram of the simulation effect of the thickness of the stator yoke/the width of the narrowest part of the stator teeth and the motor constant per unit weight when the number N of the stator teeth 102 is 48.
  • the motor constant per unit weight is about to appointment
  • the motor of the embodiment of the present disclosure having the above structure significantly improves the motor constant of the motor per unit weight, and improves the output efficiency of the motor.
  • the thickness of the stator yoke when the thickness of the stator yoke varies with the angle, the thickness of the stator yoke should be understood as the average radial thickness or the equivalent radial thickness of the stator yoke in the magnetic circuit. thickness.
  • FIG. 1 an air gap is formed between the stator 1 and the rotor 2, and the average air gap distance of the motor is g, and the average air gap distance g of the motor can be less than or Equal to 0.5% of the outer diameter d2 of the stator.
  • Fig. 7 shows a schematic diagram of the simulation effect of the ratio of the average air gap distance to the outer diameter of the stator and the motor constant per unit weight of the motor according to the embodiment of the disclosure. As shown in Figure 7, as the ratio of the average air gap distance to the outer diameter of the stator increases, the motor constant per unit weight tends to decrease gradually.
  • the motor with the above structure significantly improves the motor constant per unit weight of the motor and improves the output efficiency of the motor.
  • the average radial thickness of the permanent magnet 21 is t, and the average radial thickness t of the permanent magnet 21 may be less than or equal to 25 times the average air gap distance g , and can be greater than or equal to 5 times the average air gap distance g.
  • Fig. 8 shows a schematic diagram of the simulation effect of the ratio of the average radial thickness of the permanent magnet to the average air gap distance and the motor constant per unit weight.
  • the motor constant per unit weight can be in arrive between, compared with the motor in the prior art, the motor with the above structure significantly improves the motor constant per unit weight of the motor, and improves the output efficiency of the motor.
  • the outer diameter d2 of the stator core 10 may be less than or equal to 150 mm.
  • the axial height h of the stator core 10 may be less than or equal to 25% of the outer diameter d2 of the stator core.
  • the axial height h is Refers to the height perpendicular to the paper.
  • Fig. 9 shows a schematic diagram of the simulation effect of the ratio of the axial height h of the stator core to the outer diameter of the stator core and the motor constant per unit weight. As shown in Fig.
  • the motor constant per unit weight can be in arrive between, compared with the motor in the prior art, the motor with the above structure significantly improves the motor constant per unit weight of the motor, and improves the output efficiency of the motor.
  • the permanent magnet carrier 20 includes a cavity. As shown in FIG. 1 , the diameter dn of the cavity may be greater than or equal to 57.5% of the outer diameter d2 of the stator core.
  • the inner diameter d1 of the stator core is greater than or equal to 77.5% of the outer diameter d2 of the stator core and less than or equal to 90% of the outer diameter of the stator core.
  • FIG. 10 it is a schematic diagram of the simulation effect of the ratio of the inner diameter of the stator core to the outer diameter of the stator core and the motor constant per unit weight.
  • the motor constant per unit weight can be in arrive between, compared with the motor in the prior art, the motor with the above structure significantly improves the motor constant per unit weight of the motor, and improves the output efficiency of the motor.
  • the motor with the above-mentioned size and structure can make the manufacturing, processing and assembly of the motor less difficult, and is conducive to improving the slot filling rate and increasing the air gap area, thereby increasing the torque density of the permanent magnet brushless motor and improving the performance of the motor.
  • the width at the widest point of the stator teeth may be less than or equal to 3.4mm. In this way, the ineffective and non-working end windings can be reduced, and the operating efficiency and torque performance of the motor can be improved.
  • each stator tooth is covered with a winding coil, as shown in Figures 4A, 4B and 4C,
  • Figure 4A shows a top view of the winding coil 11
  • Figure 4B shows a view taken along the A-A line
  • Fig. 4C shows the overall view of the winding coil 11, for each stator tooth, the winding coil 11 forms several layers of wiring from the inside to the outside, wherein the winding coil layer number n is greater than zero
  • An integer of for example, may be an even number or an odd number, and the incoming wire of the winding coil is on the side close to the stator yoke.
  • the number of wiring layers refers to the maximum number of layers, and the number of wiring layers in some areas can be less than n.
  • n is an odd number, the number of turns of the outermost layer of wires may be less than or equal to 90% of the average number of turns of other layers of wires. From the inside to the outside means from the center of the stator teeth to the outside.
  • the number of turns is 73.3%, and the number of turns in the outermost layer is less than or equal to 90% of the average number of turns in other layers.
  • the wires of each of the winding coils are round wires with a circular cross section or square wires with an approximately square cross section.
  • the outer diameter of the belt skin is dc
  • the length of the belt skin side of the square line is dc
  • q is 1/2 of the arc length between the teeth ends of the adjacent stator teeth away from the stator yoke, and q is in the axial section of the stator core 1/2 of the arc length between the tooth roots of the adjacent stator teeth close to the stator yoke.
  • the half 104 of the stator slot that can accommodate the conductor can be approximately regarded as a right-angled trapezoid.
  • the cross-section of the coil can be roughly divided into a wide part and a narrow part, and maximizing the slot fill rate means maximizing the sum of the areas of the wide part and the narrow part.
  • the groove-shaped closing structure makes the arrangement of the conductors so that the coils do not interfere during the sheathing process.
  • p is 1.232
  • q is 1.658.
  • the method of calculating the slot fullness rate in this embodiment is the ratio of the cross-sectional area of the skin-containing conductor to the area of half of the stator slot 104 .
  • the slot full rate is significantly increased, up to 0.75, which is significantly improved compared with the prior art, and is of great significance for reducing the copper loss of the motor and improving the operating efficiency and torque performance.
  • the setting of the above-mentioned structural dimensions in this embodiment is proposed by the inventor after comprehensive consideration of factors such as the difficulty of process implementation, the electromagnetic performance of the motor, the actual operating conditions and application scenarios.
  • the above-mentioned optimization is made to the relevant dimensions of the motor, so that the wound coil has consistency, compactness, and safety, ensures the stable assembly and cooperation of the coil and the motor, and maximizes the use of the space of the motor slot. While the torque is low and the motor can run smoothly, the motors manufactured in large quantities have a high slot full rate and low DC and AC copper losses, thereby improving the torque density of the motor and the motor constant per unit mass.
  • the permanent magnet 21 is disposed outside the permanent magnet carrier 20 .
  • the permanent magnet is composed of several permanent magnet blocks, and the several permanent magnets form a Halbach array, and the permanent magnet carrier is a non-soft magnetic material.
  • the application of Halbach array can significantly improve the motor constant per unit mass.
  • the ratio of the number of poles P of the permanent magnet to the number of teeth N of the stator teeth, that is, P/N may be greater than or equal to 0.78 and less than or equal to 1.34.
  • the above-mentioned electromagnetic setting in this embodiment is proposed by the inventor after considering factors such as the difficulty of process implementation and the comprehensive electromagnetic performance of the motor.
  • the difficulty of manufacturing, processing and assembling of the motor is low, there are few invalid connection parts, the processing difficulty is low, it is easy to automate, the specific process is reduced, the management cost is reduced, and the motor has a wider speed regulation. Space and more general operating conditions without sacrificing the torque density and motor constant of the motor.
  • This number of tooth poles has better overall performance: lower cogging torque, running noise and better moment performance.
  • the resistance of the stator winding can be adjusted by changing the series-parallel connection of the winding coils in the stator winding to achieve the purpose of setting different operating voltages and rated speeds, which saves the trouble of changing the diameter of the motor winding coil and simplifies the manufacturing process.
  • the motor constant per unit mass of the motor provided by the embodiments of the present disclosure can reach And it has realistic manufacturing and mass production feasibility, which is significantly improved compared with the prior art.
  • the power output density of the permanent magnet brushless motor in this embodiment can reach 12 kw/kg.
  • Embodiments of the present disclosure also provide a method for manufacturing a permanent magnet brushless motor.
  • the permanent magnet brushless motor is as described above. As shown in FIG. 12 , the manufacturing method includes:
  • preparing the winding coil of the stator winding to obtain the air-core coil may include: using a winding machine to wind the enameled wire on the skeleton to form the air-core coil.
  • performing the electrical connection of the winding coils may include: connecting the winding coils according to the specified connection mode of the windings of the motor,
  • the stator includes a stator core and a stator winding.
  • the winding coil 11 forms several layers of wires from the inside to the outside, wherein the number of layers of the multi-layer wire is n layers, and the entry wire of the winding coil is near On one side of the stator yoke, where n is an integer greater than zero, when n is an odd number, the number of turns of the outermost wire is less than or equal to 90% of the average number of turns of the other inner layers.
  • Preparing the winding coil of the stator winding to obtain the air-core coil may also include: determining the range of the skinned outer diameter dc of the round wire or determining the range of the skinned side length dc of a square wire that is approximately square, so as to select the wire to Prepare the winding coil.
  • determining the range of the outer diameter dc of the strip of the round wire or determining the range of the side length dc of the strip of the square wire to select the wire to prepare the winding coil may include:
  • in or p is 1/2 of the arc length between adjacent stator teeth in the axial section of the stator core and the tooth ends away from the stator yoke
  • q is the axial section of the stator core 1/2 of the arc length between the tooth roots of adjacent stator teeth close to the stator yoke.
  • preparing the stator core may include: forming the stator core, chamfering the edge of the tooth body of the stator core, and surface treatment of the stator core.
  • the winding coils can be prepared first and then the stator core, or the stator core can be prepared first and then the winding coils can be prepared. Or both are performed simultaneously, which is not limited by the embodiments of the present disclosure.
  • the preparation of the stator core can include: the forming of the stator core can be formed by stamping silicon steel sheets and stacking them; the chamfering of the edge of the stator core tooth body refers to processing the sharp edge of the stator core tooth body The process of sharp edges, the non-sharp edges after chamfering can be obtuse edges, arc edges or other non-sharp edges, and this invention is not limited; the surface treatment of the stator core refers to the electrophoretic paint through electrochemical adhesion The process of attaching the paint film to the stator core or the stator core by vapor deposition.
  • preparing the winding coil of the stator winding to obtain the air-core coil may include: using a winding machine to wind the enameled wire on the frame to form the air-core coil.
  • a winding machine is any device that converts wire into coils.
  • the fixing of the coil and the stator core may include: sheathing and fixing the hollow coil on the completed stator core; if necessary, applying glue to the teeth of the stator core or the cavity of the hollow coil before sheathing , and cure the glue after setting; or, in other embodiments, the glue can be applied to the axial surface of the winding coil after setting, and the winding coil can be fixed by fixing the relative position of the winding coil and the winding coil It is fixed on the stator teeth without loosening.
  • the electrical connection of the coils may include: connecting the coils in a prescribed connection manner for the motor windings.
  • the electrical connection part of the coil is directly connected to the coil during the preparation process of the coil, and part is soldered on the printed circuit board; in other embodiments, the electrical connection between the coil and the coil can also be connected through the coil and the coil Air wiring, terminal wiring, aerial welding and other methods.
  • the electrical connection of the coil can occur after the fixed time sequence of the coil and the iron core; it can also be during the preparation of the coil; or before the fixing of the coil and the stator core; it can also be partially occurred between the coil and the iron core. Before the iron core is fixed, partly during the preparation of the coil, partly after the coil and the iron core are fixed.
  • An embodiment of the present disclosure also provides a robotic joint actuator, including the permanent magnet brushless motor as described above.
  • the embodiment of the present disclosure also provides a servo steering gear actuator, including the above-mentioned permanent magnet brushless motor.
  • An embodiment of the present invention also provides a robot, including the aforementioned actuator.
  • Embodiments of the present disclosure provide a permanent magnet brushless motor and its manufacturing method, a robot joint actuator, a servo servo actuator, and a robot. On the teeth, thereby avoiding the interference when the coil is wound, and improving the slot fullness rate.
  • the wire of the winding coil is determined
  • the outer diameter of the skin or the value range of the side length so as to determine the size of the wire used in the winding coil according to the stator core, etc., so that the motor obtained by winding such a wire can significantly improve the slot fill rate and improve the motor. Torque density and motor constant per unit mass.
  • the determination of the outer diameter or side length of the above-mentioned wires is coordinated with other motor structural parameters, such as the width of the narrowest part of the stator teeth, the average air gap distance, the outer diameter and inner diameter of the stator, and the motor manufacturing process.
  • the wound coils are consistent, compact, and safe, ensuring stable assembly and matching of the coil and the motor and maximizing Utilizing the space of the motor slot, the motor slots manufactured in large quantities have a high full rate and low DC and AC copper losses, thereby improving the torque density of the motor and the motor constant per unit mass.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)

Abstract

La présente invention concerne un moteur sans balais à aimant permanent (100) et son procédé de fabrication. Le moteur sans balais à aimant permanent (100) est un moteur à rotor interne à fente fractionnaire, et comprend un stator (1) et un rotor (2). Le stator (1) comprend un noyau de stator (10) et un enroulement de stator d'un enroulement centralisé non décalé ayant une étendue de 1 ; le rotor (2) comprend un support d'aimant permanent (20) et un aimant permanent (21) disposé sur le côté externe du support d'aimant permanent (20) ; le noyau de stator (10) comprend une partie culasse de stator (101) et une partie dent de stator ; la partie dent de stator comprend une pluralité de dents de stator (102) disposées sur la partie culasse de stator (101) ; une couche isolante est disposée sur la surface de chaque dent de stator (102) ; l'enroulement de stator comprend une pluralité de bobines d'enroulement (11) formées par enroulement mécanique ; et chaque bobine de la pluralité de bobines d'enroulement (11) est disposée de manière symétrique sur la dent de stator correspondante (102) en utilisant un axe central radial (103) correspondant à la dent de stator (102) comme axe de symétrie.
PCT/CN2022/113466 2021-08-19 2022-08-19 Moteur sans balais à aimant permanent et son procédé de fabrication, actionneur d'articulation et robot WO2023020601A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
CN202121953328.7 2021-08-19
CN202110956434.9A CN115714479A (zh) 2021-08-19 2021-08-19 永磁无刷电机及其制造方法、关节执行器以及机器人
CN202110956434.9 2021-08-19
CN202121953328 2021-08-19

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WO2023020601A1 true WO2023020601A1 (fr) 2023-02-23

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105186726A (zh) * 2015-07-16 2015-12-23 博格思众（常州）电机电器有限公司 无刷电机
CN210693582U (zh) * 2020-03-04 2020-06-05 上海舞肌科技有限公司 永磁无刷电机定子及包含其的电机
CN111490611A (zh) * 2020-01-07 2020-08-04 上海舞肌科技有限公司 永磁无刷电机及机器人关节、伺服舵机执行器、机器人
CN112910119A (zh) * 2021-01-19 2021-06-04 上海舞肌科技有限公司 永磁无刷电机及包含其的执行器、机器人

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105186726A (zh) * 2015-07-16 2015-12-23 博格思众（常州）电机电器有限公司 无刷电机
CN111490611A (zh) * 2020-01-07 2020-08-04 上海舞肌科技有限公司 永磁无刷电机及机器人关节、伺服舵机执行器、机器人
CN210693582U (zh) * 2020-03-04 2020-06-05 上海舞肌科技有限公司 永磁无刷电机定子及包含其的电机
CN112910119A (zh) * 2021-01-19 2021-06-04 上海舞肌科技有限公司 永磁无刷电机及包含其的执行器、机器人

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