WO2023217038A1 - 无刷电机和用于车辆座椅的气泵系统 - Google Patents

无刷电机和用于车辆座椅的气泵系统 Download PDF

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Publication number
WO2023217038A1
WO2023217038A1 PCT/CN2023/092531 CN2023092531W WO2023217038A1 WO 2023217038 A1 WO2023217038 A1 WO 2023217038A1 CN 2023092531 W CN2023092531 W CN 2023092531W WO 2023217038 A1 WO2023217038 A1 WO 2023217038A1
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WO
WIPO (PCT)
Prior art keywords
brushless motor
air pump
motor according
assembly
tooth crown
Prior art date
Application number
PCT/CN2023/092531
Other languages
English (en)
French (fr)
Inventor
谢小五
陈亮
崔伟
Original Assignee
广东肇庆爱龙威机电有限公司
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Publication of WO2023217038A1 publication Critical patent/WO2023217038A1/zh

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Classifications

    • 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
    • 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
    • H02K1/14—Stator cores with salient poles
    • H02K1/146—Stator cores with salient poles consisting of a generally annular yoke with salient poles
    • 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
    • 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
    • H02K11/215—Magnetic effect devices, e.g. Hall-effect or magneto-resistive elements
    • 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
    • H02K11/30—Structural association with control circuits or drive circuits
    • 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
    • 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
    • H02K5/22—Auxiliary parts of casings not covered by groups H02K5/06-H02K5/20, e.g. shaped to form connection boxes or terminal boxes
    • H02K5/225—Terminal boxes or connection arrangements

Definitions

  • the present invention relates to the field of motors, specifically to a brushless motor, and to an air pump system for a vehicle seat including such a brushless motor.
  • car seats are equipped with adjustable lumbar support or lateral support systems.
  • the motor drives the air pump to inflate or deflate the corresponding air bags in the lumbar support or lateral support system.
  • the purpose of adjustment is achieved through the bulge and recovery of the air bags, thereby providing better support for the passenger's waist.
  • the car seat can also be equipped with a massage system, and the motor drives the air pump to inflate or deflate the corresponding air bag to achieve the purpose of massage.
  • brushed motors In view of the price and cost advantages of brushed motors, the common motors currently on the market used to drive car seat air pumps are brushed motors.
  • a brushed motor has a carbon brush structure and relies on a commutator to reverse direction to maintain continuous operation of the motor.
  • the service life of brushed motors is usually short, and durability failure is generally around 2,000 hours.
  • brushed motors also have the disadvantages of non-speed adjustment, poor electromagnetic compatibility (EMC), large vibration and noise, low output power and low efficiency.
  • EMC electromagnetic compatibility
  • Brushless motors use electronic commutators to replace the contact mechanical commutators and carbon brushes of brushed motors, which can greatly extend the service life of the motor. It also has (pulse width modulation) PWM speed controllable and improved electromagnetic compatibility (EMC). , smaller motor noise and vibration, and higher efficiency.
  • EMC electromagnetic compatibility
  • brushless motors require a controller to operate the motor, they are more complex than brushed motors. The level of complexity increases significantly, and the cost increases accordingly.
  • the present invention provides a brushless motor that can be used in a seat air pump system.
  • a brushless motor that can be used in a seat air pump system.
  • controllable PWM speed improved EMC, smaller noise and vibration, and higher efficiency
  • the brushless motor In addition to higher advantages, it also has the advantages of low cost, strong anti-electromagnetic interference (EMI) performance and compact structure.
  • EMI anti-electromagnetic interference
  • a brushless motor including a stator assembly, a rotor assembly, a casing, an end cover and a circuit board assembly, the circuit board assembly is equipped with a brushless motor control chip.
  • the brushless motor control chip is an integrated chip integrating a switching circuit, a soft-start circuit, a driving circuit and a Hall signal detection circuit.
  • the use of integrated integrated chips to replace brushless motor controllers greatly simplifies the control circuit and saves control circuit costs. On the other hand, it also makes the motor structure more compact.
  • the circuit board assembly is built into a brushless motor arrangement, thereby improving the anti-electromagnetic interference (EMI) performance of the motor.
  • EMI anti-electromagnetic interference
  • the housing is integrally stretched and formed, which not only saves one side of the end cap, but also improves the coaxiality of the bearing seat.
  • the housing is provided with a slot, and the power cord of the circuit board assembly is led out from the slot.
  • An elastic plug such as a rubber plug, is provided between the power cord and the slot.
  • the elastic plug has an opening that allows the power cord to pass through.
  • the surface of the elastic plug is designed with convex ribs.
  • the convex ribs shrink after being subjected to the pressure of the end cover, thereby absorbing the component tolerances between the end cover, the elastic plug and the shell, and avoiding the assembly of the end cover. Inadequate situations occur.
  • the brushless motor has an inner rotor or an outer rotor structure.
  • the rotor core of the rotor assembly includes rotor laminations, and the rotor laminations adopt a hollow design to minimize the weight of the rotor while ensuring sufficient magnetization of the rotor core and rotor stiffness.
  • the angle between the teeth and the tooth crown of the stator core of the stator assembly is in the range of 115-125 degrees, preferably 120 degrees, which is conducive to the orderly arrangement of the windings in the slots and improves Slot full rate.
  • the brushless motor is used to drive an air pump in a car seat lumbar support adjustment system or a massage system.
  • the circuit board assembly integrates the ECU (electronic control unit) circuit of the air pump system, thereby making the structure more compact.
  • the brushless motor is a single-phase motor
  • the stator core of the stator assembly has an asymmetric tooth crown, which is beneficial to realizing self-starting of the motor.
  • the asymmetric tooth crown is divided into a large tooth crown and a small tooth crown along the tooth center line. There is an arc transition between the large tooth crown and the small tooth crown, so that the air gap magnetic field can be stabilized. transition, which is beneficial to suppress vibration noise.
  • the brushless motor is a single-phase motor, using 4 poles and 4 slots or 6 poles and 6 slots.
  • the brushless motor is a three-phase motor, using 4 poles and 6 slots or 8 poles and 6 slots.
  • the invention also provides an air pump system for a vehicle seat, which includes an air pump system arranged in the vehicle seat The air pump and the aforementioned brushless motor used to drive the air pump.
  • the brushless motor of the present invention uses an integrated chip integrating a switching circuit, a soft start circuit, a drive circuit and a Hall signal detection circuit to replace the controller of the existing brushless motor, thereby minimizing the use of external circuits and greatly simplifying control circuit, saving control circuit costs and making the motor more compact. Due to the reduction in cost, it is possible for brushless motors to be used in car seat air pump lumbar support systems or massage systems. In addition, by integrating the ECU (electronic control unit) circuit of the air pump system and the drive circuit of the brushless motor, the structure is made more compact.
  • ECU electronic control unit
  • the brushless motor of the present invention also has the advantages of low cost, compact structure, and anti-electromagnetic resistance.
  • Figure 1 is a perspective view of a brushless motor according to an embodiment of the present invention.
  • Figure 2 is an exploded view of the brushless motor in Figure 1;
  • Figure 3 is a perspective view of an elastic plug according to an embodiment of the present invention.
  • Figure 4 is a perspective view of a portion of the brushless motor housing assembled with the elastic plug shown in Figure 3;
  • Figure 5 is a front view of the stator core of the single-phase motor according to an embodiment of the present invention.
  • Figure 6 is a partial enlarged view of the asymmetric tooth crown of the stator core in Figure 5;
  • Figure 7 is a perspective view of a brushless motor according to an embodiment of the present invention.
  • Figure 8 is a perspective view of a brushless motor and a seat air pump assembled according to an embodiment of the present invention.
  • FIG. 1 is a perspective view of a brushless motor according to an embodiment of the present invention
  • FIG. 2 is an exploded view of the brushless motor shown in FIG. 1 .
  • the brushless motor includes a stator assembly 1, a rotor assembly 2, a housing 3, an end cover 4 and a circuit board assembly 5.
  • the circuit board assembly 5 is configured with a brushless motor control chip (not shown).
  • the exemplary brushless motor shown in FIG. 2 has an inner rotor structure, the brushless motor of the present invention may also have an outer rotor structure.
  • the brushless motor control chip is an integrated integrated chip integrating a switch circuit, a soft start circuit, a drive circuit and a Hall signal detection circuit.
  • the brushless motor of the present invention uses an integrated integrated chip to replace the controller of the existing brushless motor, which minimizes the use of external circuits, greatly simplifies the control circuit, saves the cost of the control circuit, and makes the structure of the motor more compact.
  • the circuit board assembly 5 is built into the motor. As shown in Figure 2, the circuit board assembly 5 is arranged in the motor housing 3, located on one side of the end cover 4. By disposing the circuit board assembly 5 inside the motor housing 3, the anti-electromagnetic interference (EMI) performance of the motor can be improved.
  • EMI anti-electromagnetic interference
  • the casing 3 of the brushless motor is integrally stretched, so that only one end cover 4 is required on one side of the motor, which saves the end cover on the other side and improves the durability of the bearing seat. Concentricity.
  • Figure 3 is a perspective view of the elastic plug 12 according to an embodiment of the present invention.
  • 4 is a perspective view showing that the elastic plug 12 is assembled in the motor housing 3.
  • the motor housing 3 is provided with a slot, and the power cord of the circuit board assembly 5 is led out from the slot.
  • an elastic plug 12 such as a rubber plug, is provided between the power cord and the slot of the housing 3.
  • the elastic plug 12 is designed with ribs. As shown in FIG. 3 , for example, three ribs may be provided on the upper surface of the elastic plug 12 . During the assembly process, the convex ribs shrink under the pressure of the end cover 4, thereby absorbing the component tolerances between the end cover 4, the elastic plug 12, and the shell 3, and preventing the end cover 4 from not being assembled in place.
  • the rotor core of the rotor assembly 2 includes rotor laminations, and the rotor laminations adopt a hollow design to minimize the rotor core stress and ensure the rotor stiffness. the weight of.
  • the brushless motor is a single-phase motor, and the rotor core of the single-phase motor adopts an asymmetric tooth crown structure.
  • Figure 5 is a front view of the stator core of the single-phase motor according to an embodiment of the present invention
  • Figure 6 is a partial enlarged view of the asymmetric tooth crown of the stator core in Figure 5.
  • the angle between the teeth of the stator core and the tooth crown is preferably designed to be 120 degrees, which facilitates the orderly arrangement of the windings in the slot and improves the slot filling rate.
  • the stator core of the single-phase motor adopts an asymmetric tooth crown structure.
  • the asymmetric tooth crown is divided into a large tooth crown and a small tooth crown along the tooth center line.
  • Arc transition is specifically designed to use two arc transitions, so that the air gap magnetic field can transition smoothly, which is beneficial to suppressing vibration noise.
  • the invention also relates to the application of brushless motors in air pump lumbar support adjustment systems and massage systems of automobile seats.
  • FIG. 7 is a perspective view of a brushless motor according to an embodiment of the present invention
  • FIG. 8 is a perspective view of an assembly of a brushless motor and a seat air pump according to an embodiment of the present invention.
  • a flat section is designed on one side of the rotating shaft 23 of the brushless motor.
  • a part of the outer periphery of the flat section has a flat profile for direct contact with the air pump eccentric. (not shown in the figure) connection.
  • a threaded hole is provided on one side of the motor housing 3 so that the motor and the air pump can be connected through screws.
  • Figure 8 shows a schematic diagram of the brushless motor and air pump of the present invention after assembly.
  • the drive circuit of the brushless motor of the present invention can be integrated with the ECU (electronic control unit) circuit of the air pump system.
  • the ECU circuit of the air pump system is integrated into the circuit board assembly of the brushless motor. on, thus making the structure of the air pump system more compact.
  • the brushless motor is a single-phase motor, using 4 poles and 4 slots or 6 poles and 6 slots.
  • the brushless motor is a three-phase motor
  • the stator core of the stator assembly adopts a symmetrical tooth shape, which can be 4 poles and 6 slots or 8 poles and 6 slots.
  • the durability of the motor is increased by more than 4 times, up to about 10,000 hours. .
  • the electromagnetic compatibility (EMC) of the motor meets the level 5 requirements of the CISPR25 standard.
  • the PWM speed of the motor is controllable, and the motor noise and vibration are smaller.
  • the noise is less than 35dBA, the vibration amplitude is less than 2m/s 2 in the X and Y directions, and less than 1m/s 2 in the Z direction.
  • the motor efficiency is higher, and the efficiency of the brushless motor of the present invention is 60% to 80%.
  • the size of the motor is reduced and the structure is more compact.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Connection Of Motors, Electrical Generators, Mechanical Devices, And The Like (AREA)

Abstract

提供一种无刷电机，包括定子组件（1）、转子组件（2）、外壳（3）、端盖（4）和电路板组件（5），电路板组件（5）配置有配置成一体集成芯片的无刷电机控制芯片。还涉及一种用于车辆座椅的气泵系统，包括设置在车辆座椅中的气泵和用于驱动气泵的无刷电机。无刷电机除了具有普通无刷电机使用寿命长、PWM速度可控、电磁兼容性提高、电机噪音和振动更小以及效率更高的优点外，还具有成本低、结构紧凑以及抗电磁干扰性能强的优点。

Description

无刷电机和用于车辆座椅的气泵系统 技术领域
本发明涉及电机领域，具体来说，涉及一种无刷电机，还涉及包括这种无刷电机的用于车辆座椅的气泵系统。
背景技术
为提高驾驶者或乘客的乘坐舒适性，缓解驾驶疲劳，汽车座椅设置有可调节腰托或侧向支撑系统。对于电动可调节气泵式腰托，由电机驱动气泵向腰托或侧向支撑系统相应的气囊充气或放气，通过气囊的隆起和复原达到调节的目的，从而给乘客腰部提供更好的支撑。此外，汽车座椅还可设置按摩系统，由电机驱动气泵给相应的气囊充气或放气，达到按摩的目的。
鉴于有刷电机的价格和成本优势，目前市面上常见的用于驱动汽车座椅气泵的电机均为有刷电机。有刷电机具有碳刷结构，靠换向器换向维持电机持续运转。然而由于碳刷存在磨损消耗，有刷电机的使用寿命通常较短，耐久失效普遍在2000小时左右。此外，有刷电机还存在不可调速、电磁兼容性(EMC)差、振动和噪音大、以及输出功率小、效率低的缺点。
无刷电机使用电子换向器替代有刷电机的接触式机械换向器和碳刷，可大大提高电机的使用寿命，同时具有(脉冲宽度调制)PWM速度可控、电磁兼容性(EMC)提高、电机噪音和振动更小、以及效率更高等优点。然而由于无刷电机需要使用控制器实现电机的运转，相比有刷电机，其复 杂程度明显提高，成本相应地大大增加。
因此，在汽车座椅气泵式腰托和按摩系统中，需要一种低成本的无刷电机。
发明内容
为解决上述问题，本发明提供一种可用于座椅气泵系统的无刷电机，该无刷电机除了具有普通无刷电机使用寿命长、PWM速度可控、EMC提高、噪音和振动更小以及效率更高的优势外，还具有成本低、抗电磁干扰(EMI)性能强以及结构紧凑的优点。
本发明的目的通过以下技术方案实现：一种无刷电机，包括定子组件、转子组件、外壳、端盖和电路板组件，所述电路板组件配置有无刷电机控制芯片。
根据本发明的一个方面，所述无刷电机控制芯片是集开关电路、软启动电路、驱动电路和霍尔信号检测电路于一体的一体化集成芯片。使用一体化集成芯片替代无刷电机控制器，一方面大大简化了控制电路，节省控制电路成本，另一方面也使得电机的结构更加紧凑。
根据本发明的一个方面，所述电路板组件内置于无刷电机设置，从而提高电机的抗电磁干扰(EMI)性能。
根据本发明的一个方面，所述外壳为一体拉伸成型，节省一侧端盖的同时，还可提高轴承座的同轴度。
根据本发明的一个方面，所述外壳设有开槽，所述电路板组件的电源线从开槽处引出。所述电源线和开槽之间设置有弹性塞，例如胶塞，所述弹性塞具有允许所述电源线通过的开孔。通过设置弹性塞，在电机端盖和外壳装配时会压缩弹性塞，使弹性塞和电源线之间形成摩擦力，从而使得 电源线具有一定的抗拉拔能力。
根据本发明的一个方面，所述弹性塞表面设计有凸筋，在装配过程中，凸筋受到端盖压力后收缩，从而吸收端盖、弹性塞、外壳之间的零件公差，避免端盖装配不到位的情况发生。
根据本发明的一个方面，所述无刷电机为内转子或外转子结构。
根据本发明的一个方面，所述转子组件的转子铁芯包括转子叠片，转子叠片采用镂空式设计，保证转子铁芯充分走磁和转子刚度的件下最大限度地减轻转子的重量。
根据本发明的一个方面，所述定子组件的定子铁芯的齿与齿冠之间的角度在115-125度的范围内，优选120度，从而有利于绕线在槽内有序排列，提高槽满率。
根据本发明的一个方面，所述无刷电机用于驱动汽车座椅腰托调节系统或者按摩系统中的气泵。所述电路板组件集成有所述气泵系统的ECU(电子控制单元)电路，从而使得结构更加紧凑。
根据本发明的一个方面，所述无刷电机为单相电机，所述定子组件的定子铁芯具有不对称齿冠，有利于实现电机自启动。
根据本发明的一个方面，所述不对称齿冠沿齿中心线分为大齿冠和小齿冠，所述大齿冠和小齿冠之间为圆弧过渡，从而使得气隙磁场可以平稳过渡，有利于抑制振动噪音。
根据本发明的一个方面，所述无刷电机为单相电机，采用4极4槽或者6极6槽。
根据本发明的一个方面，所述无刷电机为三相电机，采用4极6槽或者8极6槽。
本发明还提供一种用于车辆座椅的气泵系统，包括设置在车辆座椅中 的气泵和用于驱动所述气泵的前述无刷电机。
本发明的无刷电机使用集开关电路、软启动电路、驱动电路和霍尔信号检测电路于一体的集成芯片代替现有无刷电机的控制器，最大程度上减少外在电路使用，大大简化了控制电路，节省控制电路成本，同时使得电机的结构更加紧凑。由于成本的降低，使得无刷电机应用于汽车座椅气泵式腰托系统或按摩系统成为可能。此外，通过将气泵系统的ECU(电子控制单元)电路与无刷电机的驱动电路整合在一起，使得结构更加紧凑。本发明的无刷电机除了具有普通无刷电机使用寿命长、PWM速度可控、电磁兼容性提高、电机噪音和振动更小以及效率更高的优点外，还具有成本低、结构紧凑以及抗电磁干扰性能强的优点。
附图说明
图1为根据本发明实施例的无刷电机透视图；
图2为图1中无刷电机的分解视图；
图3为根据本发明实施例的弹性塞的透视图；
图4为组装有图3所示弹性塞的无刷电机外壳的一部分的透视图；
图5为根据本发明实施例的单相电机的定子铁芯的正视图；
图6为图5中定子铁芯不对称齿冠的局部放大图；
图7为根据本发明实施例的无刷电机透视图；
图8为根据本发明实施例的无刷电机与座椅气泵组装的透视图。
具体实施方式
下面分别结合附图对本发明的无刷电机作进一步的详细说明，这些附图通过举例的方式示出本发明的实施例。
在下面的描述中，阐述了许多具体细节以便使所属技术领域的技术使用者更全面地了解本发明。但是，对于所属技术领域内的技术使用者明显的是，本发明的实现可不具有这些具体细节中的一些。此外，应当理解的是，本发明并不限于所介绍的特定实施例。相反，可以考虑用下面的特征和要素的任意组合来实施本发明，而无论它们是否涉及不同的实施例。因此，下面的方面、特征、实施例和优点仅作说明之用而不应被看作是权利要求的要素或限定，除非在权利要求中明确提出。
参照图1和图2，图1为根据本发明实施例的无刷电机的透视图，图2为图1所示无刷电机的分解视图。
如图2所示，作为本发明的一个实施例，无刷电机包括定子组件1、转子组件2、外壳3、端盖4和电路板组件5，所述电路板组件5配置有无刷电机控制芯片(图中未示出)。虽然图2所示的示例性无刷电机为内转子结构，本发明的无刷电机也可以为外转子结构。
所述无刷电机控制芯片是集开关电路、软启动电路、驱动电路和霍尔信号检测电路于一体的一体化集成芯片。本发明的无刷电机使用一体化集成芯片替代现有无刷电机的控制器，最大程度上减少外在电路使用，大大简化了控制电路，节省控制电路成本，同时使得电机的结构更加紧凑。
作为一种具体的实施方式，所述电路板组件5内置于电机。如图2所示，电路板组件5设置在电机外壳3内，位于端盖4一侧。通过将电路板组件5设置在电机壳体3内部，可提高电机的抗电磁干扰(EMI)性能。
作为一种具体的实施方式，所述无刷电机的外壳3为一体拉伸成型，从而仅需在电机的一侧设置端盖4，节省另一侧端盖的同时，还可提高轴承座的同轴度。
参见图3和图4，图3为根据本发明实施例的弹性塞12的透视图，图 4为示出弹性塞12组装于电机外壳3的透视图。
如图4所示，所述电机外壳3设有开槽，所述电路板组件5的电源线从开槽处引出。作为一种具体的实施方式，在电源线和外壳3的开槽之间设置有弹性塞12，例如胶塞。通过设置弹性塞12，在电机端盖4与外壳3装配时会压缩弹性塞12，使弹性塞12和电源线之间形成摩擦力，从而使得电源线具有一定的抗拉拔能力。
作为一种具体的实施方式，所述弹性塞12设计有凸筋。如图3所示，例如可以在弹性塞12的上表面设置三个凸筋。在装配过程中，所述凸筋受到端盖4的压力后收缩，从而吸收端盖4、弹性塞12、外壳3之间的零件公差，避免端盖4装配不到位的情况发生。
作为一种具体的实施方式，所述转子组件2的转子铁芯包括转子叠片，转子叠片采用镂空式设计，在保证转子铁芯充分走磁和转子刚度的条件下，最大限度地减轻转子的重量。
作为一种具体的实施方式，所述无刷电机为单相电机，所述单相电机的转子铁芯采用不对称齿冠结构。参见图5和图6，图5为根据本发明实施例的单相电机的定子铁芯正视图，图6为图5中定子铁芯不对称齿冠的局部放大图。
如图5所示，作为一种具体的实施例，定子铁芯的齿与齿冠之间的角度优选设计为120度，从而有利于绕线在槽内有序排列，可以提高槽满率。
如图6所示，所述单相电机的定子铁芯采用不对称的齿冠结构，所述不对称齿冠沿齿中心线分为大齿冠和小齿冠。通过采用不对称齿冠的设计，电机与泵头组装后在极端工况下，仍然可以提供充足的启动扭矩，实现电机自启动。
如图6所示，作为一种具体的实施例，所述大齿冠和小齿冠之间为圆 弧过渡，具体设计为使用两段圆弧过渡，从而使得气隙磁场可以平稳过渡，有利于抑制振动噪音。
本发明还涉及无刷电机在汽车座椅的气泵式腰托调节系统和按摩系统中的应用。
参见图7和图8，图7为根据本发明实施例的无刷电机透视图，图8为根据本发明实施例的无刷电机与座椅气泵组装的透视图。
如图7所示，作为一种具体的实施方式，在无刷电机的转轴23一侧设计扁位部段，该扁位部段的一部分外周具有平坦的廓形，用于直接同气泵偏心轮(图中未示出)连接。电机外壳3一侧设置有螺纹孔，使电机与气泵通过螺丝进行连接。图8示出本发明的无刷电机与气泵组装后的示意图。
作为一种具体的实施方式，可以将本发明无刷电机的驱动电路与气泵系统的ECU(电子控制单元)电路整合在一起，具体为将气泵系统的ECU电路集成在无刷电机的电路板组件上，从而使得气泵系统的结构更加紧凑。
作为一种具体的实施方式，所述无刷电机为单相电机，采用4极4槽或者6极6槽。
作为一种具体的实施方式，所述无刷电机为三相电机，定子组件的定子铁芯采用对称齿型，可以为4极6槽或者8极6槽。
在汽车座椅气泵式腰托调节系统或者按摩系统中使用本发明的无刷电机驱动气泵，相比现有技术中使用的有刷电机而言，电机耐久提升4倍以上，可达10000小时左右。电机的电磁兼容性(EMC)满足CISPR25标准5级要求。电机的PWM速度可控，电机噪音及振动更小。噪音小于35dBA，振动幅度在X和Y方向均小于2m/s2，在Z方向小于1m/s2。电机效率更高，本发明的无刷电机效率为60％～80％。此外，电机的尺寸减小，结构更加紧凑。
虽然本发明已以较佳实施例披露如上，但本发明并非限定于此。任何本领域技术使用者，在不脱离本发明的精神和范围内所作的各种更动与修改，均应纳入本发明的保护范围，本发明的保护范围应当以权利要求所限定的范围为准。

Claims (16)

  1. 一种无刷电机，包括定子组件、转子组件、外壳、端盖和电路板组件，其特征在于，所述电路板组件配置有无刷电机控制芯片。
  2. 根据权利要求1所述的无刷电机，其特征在于，所述控制芯片集成有开关电路、软启动电路、驱动电路和霍尔信号检测电路。
  3. 根据权利要求2所述的无刷电机，其特征在于，所述电路板组件位于所述外壳内。
  4. 根据权利要求3所述的无刷电机，其特征在于，所述外壳为一体拉伸成型。
  5. 根据权利要求4所述的无刷电机，其特征在于，所述外壳设有开槽，所述开槽上设置弹性塞，所述电路板组件的电源线从所述弹性塞引出。
  6. 根据权利要求5所述的无刷电机，其特征在于，所述弹性塞具有凸筋。
  7. 根据权利要求6所述的无刷电机，其特征在于，所述转子组件包括转子叠片，所述转子叠片具有镂空。
  8. 根据权利要求7所述的无刷电机，其特征在于，所述定子组件具有定子铁芯，所述定子铁芯的齿与齿冠之间的角度为115-125度。
  9. 根据权利要求8所述的无刷电机，其特征在于，所述无刷电机为内转子或外转子结构。
  10. 根据权利要求1-8中任一项所述的无刷电机，其特征在于，所述无刷电机用于驱动座椅腰托调节系统或者按摩系统中的气泵。
  11. 根据权利要求10所述的无刷电机，其特征在于，所述电路板组件集成有所述气泵系统的ECU电路。
  12. 根据权利要求11所述的无刷电机，其特征在于，所述电机为单相电机，所述定子组件的定子铁芯具有不对称齿冠。
  13. 根据权利要求12所述的无刷电机，其特征在于，所述不对称齿冠沿齿中心线分为大齿冠和小齿冠，所述大齿冠和小齿冠之间为圆弧过渡。
  14. 根据权利要求11-13中任一项所述的无刷电机，其特征在于，所述电机为4极4槽或者6极6槽。
  15. 根据权利要求11所述的无刷电机，其特征在于，所述电机为三相电机，采用4极6槽或者8极6槽。
  16. 一种用于车辆座椅的气泵系统，其特征在于，所述气泵系统包括设置在车辆座椅中的气泵和用于驱动所述气泵的根据权利要求1至15中任一项所述的无刷电机。
PCT/CN2023/092531 2022-05-10 2023-05-06 无刷电机和用于车辆座椅的气泵系统 WO2023217038A1 (zh)

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