A stator structure based on disc-type permanent magnet motor winding

Abstract

The invention discloses a stator structure based on a disk-type permanent magnet motor winding, comprising: a PCB board with at least 6 layers or 6N layers, and a Hall sensor; each layer of the PCB board is provided with: multiple groups of outer ends, a winding setting part, and multiple groups of inner ends; each layer of the PCB board is provided with at least three-phase windings, and each phase of the winding is respectively provided with two wiring terminals; the wiring terminals are provided on the outer ends; each phase winding coil is printed and arranged from the corresponding outer end; the winding coil is uniformly printed on the winding setting part along the circumference, and the length of the winding coil is printed in parallel along the radial direction, and is arranged in parallel without overlapping; the winding coils of the same phase arranged on each layer of the PCB board are connected through the outer ends and the inner ends; the Hall sensor is arranged on the outer ends at an angle; and the layers in the PCB board are connected through vias.

Description

Technical Field

[0001] The invention relates to the field of motors, and in particular to a stator structure based on a disc-type permanent magnet motor winding. Background Art

[0002] The disc motor is different from the traditional radial motor. The stator and rotor of the disc motor are arranged along the axial direction. There are single rotor and single stator, intermediate stator, multi-disk and other structures. Traditional radial motors have some difficulties that are not easy to solve, such as torque pulsation, poor heat dissipation, low utilization rate of rotor core, etc. Therefore, disc motors have received more and more attention since the 1940s. At present, disc motors are widely used in flywheel energy storage systems, mechatronics equipment and other fields. PCB stator disc permanent magnet motor is a combination of printed circuit board technology and disc motor technology. The stator adopts PCB technology and has no stator core, so the motor is simple to produce and manufacture, small size, light weight, high power density, small torque pulsation, and compact motor structure.

[0003] The key to the design of PCB stator disc permanent magnet motor is the design of PCB winding. The design of winding is closely related to the production process of printed circuit board, motor output performance, motor air gap size, amount of permanent magnet material and motor size. For the traditional wiring method, since there are effective conductors in each layer, there is only one layer at the outer end and two layers at the inner end. Therefore, under the same current density, the outer end is generally 6 times larger than the effective conductor, and the inner end is 3 degrees wider than the effective conductor width. The inner and outer ends will occupy a large space, which reduces the utilization rate of the stator and affects the output. For the inner diameter where the space is already narrow, it will appear very "crowded", making wiring more difficult, affecting heat dissipation, and limiting the increase in current, especially when there are more slots per pole per phase, this effect will be more significant. The more slots per pole per phase, the more ends, the larger the space occupied, the greater the copper loss, the lower the efficiency, and it becomes difficult to increase the power density.

[0004] Therefore, based on the above existing technical problems, the present invention provides a technical solution to solve the above technical problems. Summary of the invention

[0005] The purpose of the present invention is to provide a stator structure based on a disc permanent magnet motor winding. The stator structure of the present invention greatly reduces the end length and the space occupied, makes wiring at the inner diameter convenient, is conducive to the flow of large current, and improves the effective utilization rate of the stator when the outer diameter of the stator is constant.

[0006] The technical solution provided by the present invention is as follows:

[0007] A stator structure based on a disk-type permanent magnet motor winding comprises: a PCB board with at least 6 layers or 6N layers, and a Hall sensor; each layer of the PCB board is provided with: multiple groups of outer ends, a winding setting part, and multiple groups of inner ends; each layer of the PCB board is provided with at least three-phase windings, and each phase of the winding is respectively provided with two connection terminals; the connection terminals are provided on the outer ends; each phase winding coil is printed and arranged from the corresponding outer end; the winding coil is uniformly printed on the winding setting part along the circumference, and the length of the winding coil is printed in parallel along the radial direction, and is arranged in parallel without overlapping; the winding coils of the same phase arranged on each layer of the PCB board are connected through the outer ends and the inner ends; the Hall sensor is arranged at an angle on the outer ends; and the layers in the PCB board are connected through vias.

[0008] Specifically, the winding of the connection method adopted can make full use of the space of the stator plate, reduce the size of the stator plate, and at the same time, the effective conductors at the same position of each layer are connected in parallel through vias, which can increase the conduction current and reduce the winding resistance; it also reduces the resistance and copper loss of each phase winding, and correspondingly improves the efficiency and output power. At the same time, a Hall sensor installed at an angle is set on the stator plate, which can detect the position of the rotor in real time, and can further improve the motor control according to the rotor position, and can also extend the life of the motor and reduce costs.

[0009] Further preferably, the outer end portions are arranged circumferentially along the outer diameter of the winding setting portion and are arranged in an arc; the inner end portions are arranged circumferentially along the inner diameter of the winding setting portion and are arranged in an arc.

[0010] Further preferably, the invention comprises: a plurality of outer end conductors are arranged on each group of the outer end portions, and the number of the outer end conductors in each group is equal; a plurality of inner end conductors are arranged on each group of the inner end portions, and the number of the inner end conductors arranged on two adjacent groups of the inner end portions is unequal.

[0011] Further preferably, the method includes: two ends of the outer end conductor are respectively connected to two different conductors on the winding setting part; and two ends of the inner end conductor are respectively connected to two conductors on the winding setting part.

[0012] Further preferably, it includes: the winding setting part of each layer of the PCB board is provided with multiple conductors, one end of each of the conductors is connected to the outer end conductor, and the other end is connected to the inner end conductor; the multiple conductors are connected to each other through the corresponding multiple outer end conductors and the corresponding multiple inner end conductors to form the winding coil of the same phase.

[0013] Further preferably, the winding coils printed on the winding arrangement portion of each layer of the PCB board are arranged in a staggered manner in sequence according to different numbers of winding phases.

[0014] Further preferably, the conductors constituting the winding coils of the same phase and the same layer of the PCB board are connected in a non-concentric spiral shape.

[0015] Further preferably, the via holes are arranged at the upper edges of the inner diameter and the outer diameter of the winding arrangement portion, and each via hole is arranged at two ends of the conductor respectively; and is used to connect the conductors at the same corresponding positions.

[0016] Further preferably, the conductors on the winding arrangement portion on the same layer of the PCB board are connected in parallel and / or in series.

[0017] Further preferably, the PCB board is arranged in a circular shape.

[0018] The stator structure based on the disc-type permanent magnet motor winding provided by the present invention brings at least one of the following beneficial effects:

[0019] In the present invention, the effective conductors at the same position of each layer are connected in parallel through vias, which can increase the conduction current and reduce the winding resistance; the winding end is wider to connect the conductors of the coil group. Each coil of the winding is of full pitch, and compared with the non-overlapping concentrated winding, the effective utilization rate of the stator is improved, and the no-load back electromotive force will be larger under the same air gap flux density.

[0020] In the present invention, the winding arrangement method of the invention is a distributed winding, which can make full use of the space under the permanent magnet. The short-distance coefficient is 1, the winding coefficient is increased, the output performance will be improved, the overall copper loss of the winding is low, and the corresponding efficiency and power density will be improved.

[0021] In the present invention, the coil group in the stator plate winding is not composed of a single concentric coil, but each conductor is connected to the conductor closest to it, so that the end is relatively short, the loss is reduced, and the output performance is improved. In addition, the space of the stator plate is fully utilized, and the volume of the stator and even the motor is reduced. It has great advantages in occasions with high space requirements.

[0022] In the present invention, the stator winding connection method increases the no-load back electromotive force when the stator outer diameter is constant, and the efficiency is improved due to the reduction of copper loss, and the output power under load is also increased.

[0023] In the present invention, since the space of the stator plate is more fully utilized, the structure of the motor is more compact, which has great advantages in occasions with high space requirements.

[0024] In the present invention, there is a larger space at the inner diameter of the stator winding, which makes the wiring here more convenient and flexible, and the heat dissipation of the winding here is also improved.

[0025] In the present invention, the inner diameter of the stator winding has a larger space, which improves the heat dissipation capacity, facilitates the wire output, and the end is shorter and smaller, with less copper loss and higher efficiency, which is beneficial to the improvement of the power density of the motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The preferred implementation scheme will be described below in a clear and understandable manner in conjunction with the accompanying drawings to further illustrate the above-mentioned characteristics, technical features, advantages and implementation methods of a stator structure based on a disc-type permanent magnet motor winding.

[0027] Figure 1 It is a structural diagram of an embodiment of a stator structure based on a disc-type permanent magnet motor winding of the present invention;

[0028] Figure 2 It is a circuit diagram of another embodiment of a stator structure based on a disc-type permanent magnet motor winding of the present invention;

[0029] Figure 3 is a circuit diagram of another embodiment of a stator structure based on a disc-type permanent magnet motor winding of the present invention;

[0030] Figure 4 It is a circuit diagram of another embodiment of a stator structure based on a disc-type permanent magnet motor winding according to the present invention. DETAILED DESCRIPTION

[0031] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the specific implementation methods of the present invention will be described below with reference to the accompanying drawings. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings and other implementation methods can be obtained based on these drawings without creative work.

[0032] In order to simplify the drawings, each figure only schematically shows the parts related to the present invention, which do not represent the actual structure of the product.

[0033] The present invention provides a stator structure based on a disc-type permanent magnet motor winding, referring to Figure 1As shown; comprising: a PCB board of at least 6 layers or 6N layers, and a Hall sensor; each layer of the PCB board is provided with: multiple groups of outer ends, a winding setting part, and multiple groups of inner ends; each layer of the PCB board is provided with at least three-phase windings, and each phase of the winding is respectively provided with two terminal terminals; the terminal terminals are provided on the outer ends; each phase winding coil is printed and arranged from the corresponding outer end; the winding coil is uniformly printed on the winding setting part along the circumference, and the length of the winding coil is printed in parallel along the radial direction, and is arranged in parallel without overlapping; the winding coils of the same phase arranged on each layer of the PCB board are connected through the outer ends and the inner ends; the Hall sensor is provided at an angle on the outer ends; and the layers in the PCB board are connected through vias. Figure 4 This is a schematic diagram of the positions of the three position sensor Hall ICs, with a difference of 120°. 7 and 8 are the positive and negative power supply terminals of the three Hall ICs, and 9, 10, and 11 are the position signal output terminals of Hall H1, H2, and H3 respectively.

[0034] Specifically, in the embodiment of the present invention, the number of layers of the PCB circuit board is a multiple of 6. In this embodiment, 6 layers are taken as an example. The lead wires of the windings are respectively led out from the winding setting part, and the outer wires and the inner wires are correspondingly arranged at the outer end and the inner end, and the conductors correspondingly arranged at the same position of each layer are connected in parallel through vias. The conductors of each layer are divided into at least three phases, and each phase is divided into a plurality of coil groups. These plurality of coil groups are generally connected in series to form a phase winding. In this embodiment, for example, three phases A, B, and C are arranged on the stator, and three phases are arranged on each layer of the PCB. Each of the six layers of the PCB board is connected together to form three phases of the stator winding. Each phase corresponds to two wiring terminals, namely: B-, B+, A+, A-, C-, C+, corresponding to the numbers 1, 2, 3, 4, 5, and 6 in the figure; in the present invention, the wiring terminal is arranged on the outside of the outer end, and the winding coil is wound from the outer end, the winding setting part, and the inner end in sequence; this method makes the number of conductors on each group of the outer end and the inner end unequal; refer to Figure 1 As shown; each layer of the PCB board is provided with an outer end 3, a winding setting part 1, and an inner end 2; each phase winding coil is connected and wound by the conductors set on the outer end, the winding setting part, and the inner end; adjacent layers in the PCB board are connected through vias. In addition, a Hall sensor, i.e., a Hall IC, is arranged at an angle at the outer diameter of the surface of the PCB board of the present application. The three Hall ICs are surface-mounted, and the Hall ICs are placed on the outside of the magnetic steel (i.e., at the winding end) at an angle of 120°.

[0035] In the present invention, the winding of the connection method adopted can make full use of the space of the stator plate, reduce the size of the stator plate, and at the same time, the effective conductors at the same position of each layer are connected in parallel through vias, which can increase the conduction current and reduce the winding resistance; it also reduces the resistance and copper loss of each phase winding, and correspondingly improves the efficiency and output power. At the same time, a Hall sensor installed at an angle is provided on the stator plate, which can detect the position of the rotor in real time, can further improve the motor control according to the rotor position, and can also extend the motor life and reduce costs.

[0036] The present invention also provides an embodiment, referring to Figure 2 As shown in the figure, the outer end portions 300 are arranged along the outer diameter of the winding setting portion and are arranged in an arc; the inner end portions 200 are arranged along the inner diameter of the winding setting portion and are arranged in an arc. The outer end portion, the inner end portion, and the winding setting portion are the same entity and constitute the same layer of the PCB board.

[0037] Preferably, it includes: a plurality of outer end conductors 24, 26, etc. are arranged on each group of outer end portions 3, and the number of outer end conductors in each group is equal; a plurality of inner end conductors 23, 22, etc. are arranged on each group of inner end portions, and the number of inner end conductors arranged on two adjacent groups of inner end portions is different. For example, the inner end portions 100 and 200 in the dotted frame; there are 3 inner end conductors in the inner end portion 100, and there are 2 inner end conductors in the inner end portion 200. Since the starting positions of the windings for coil wiring are different in the present invention, the number of adjacent inner end conductors is set to be different.

[0038] The present invention also provides an embodiment of the winding coil arrangement; Figure 2 As shown; the two ends of the outer end conductor are respectively connected to two different conductors on the winding setting part; the two ends of the inner end conductor are respectively connected to the two conductors on the winding setting part.

[0039] Preferably, it includes: the winding setting part of each layer of the PCB board is provided with multiple conductors, one end of each of the conductors is connected to the outer end conductor, and the other end is connected to the inner end conductor; the multiple conductors are connected to each other through the corresponding multiple outer end conductors and the multiple inner end conductors to form the winding coil of the same phase.

[0040] Specifically, refer to Figure 2-3 As shown; Terminal A - The outer end conductor 27 begins to be wound and wired; the two ends of the outer end conductor 28 are respectively connected to two different conductors 130 and 115 on the winding setting part; the two ends of the inner end conductor 22 are respectively connected to the two conductors 205 and 194 on the winding setting part. This is equivalent to one end of a wire being connected to one end of the outer end and the other end being connected to the inner end.

[0041] Preferably, it includes: the winding coils printed on the winding setting part of each layer of the PCB board are arranged in a staggered manner according to the different phase numbers of the windings.

[0042] Preferably, the conductors constituting the winding coils of the same phase and the same layer of the PCB board are connected in a non-concentric spiral shape.

[0043] The coil group in the stator plate winding is not composed of a single concentric coil, but each conductor is connected to the conductor closest to it, which makes the end relatively short, reduces losses and improves output performance.

[0044] Preferably, the via holes are arranged at the upper edges of the inner diameter and the outer diameter of the winding arrangement portion, and each via hole is arranged at two ends of the conductor respectively; and is used to connect the conductors at the same corresponding positions.

[0045] Preferably, it includes: the conductors on the winding arrangement parts on the same layer of the PCB board are connected in parallel and / or in series.

[0046] The conductors constituting the same phase on the same layer of the PCB are arranged in series if they are not adjacent to each other, and then connected in parallel with the conductors constituting the same phase on the adjacent layer through vias; the conductors constituting different phases on the same layer of the PCB may also be connected in parallel.

[0047] Preferably, the PCB board is arranged in a circular shape.

[0048] In the present invention, the embodiment of winding coil winding; Figure 1 This is a three-dimensional schematic diagram of the windings of phases A and B of the stator plate. In order to see the details of the winding connection, Figure 1 Only the windings of phases A and B are shown. Each phase consists of several layers of coils. Each layer of coils consists of several effective conductors 13 and several inner and outer ends 16 and 15. The layers are connected together through vias 14. 1, 2, 3, 4, 5, and 6 are the connection terminals of B-, B+, A+, A-, C-, and C+ respectively. Taking phase A as an example, Figure 2 This is the distribution diagram of the upper winding of phase A. Figure 3Schematic diagram of the distribution of the lower winding of phase A. The current flows in from the positive terminal 3 of phase A, enters the effective conductor 205 through the outer end conductor 20, flows into the effective conductor 194 through the inner end 22, then leaves the upper layer of the phase A winding through the via 21A and enters the lower layer of the phase A winding, flows into the effective conductor 206 through the outer end conductor 30, flows into the effective conductor 193 through the inner end conductor 31, flows into the effective conductor 207 through the outer end conductor 32, flows into the effective conductor 192 through the inner end conductor 33, flows into the effective conductor 178 through the outer end conductor 34, enters the effective conductor 191 through the inner end conductor 37, enters the effective conductor 179 through the outer end conductor 35, and flows into the effective conductor 190 through the outer end conductor 36, forming the winding coil 1. According to the same connection method, the effective conductors 175, 164, 176, 163, 177, 162, 148, 161, 149, 160 are connected in sequence to form the winding coil 2. The effective conductors 145, 134, 146, 133, 147, 132, 118, 131, 119, 130 are connected in sequence to form winding coil 3. The effective conductors 115, 104, 116, 103, 117, 102, 208, 101, 209, 100 are connected in sequence to form winding coil 4. Similarly, the A and B phase effective conductors are connected to form the A phase and B phase windings respectively.

[0049] In the present invention, the effective conductors at the same position of each layer are connected in parallel through vias, which can increase the conduction current and reduce the winding resistance. The wider end of the winding is used to connect the conductors of the coil group. Each coil of the winding is full pitch, and compared with the non-overlapping concentrated winding, the effective utilization rate of the stator is improved. Under the same air gap flux density, the no-load back electromotive force will be larger. Compared with the non-overlapping concentrated winding, the distributed winding can make full use of the space under the permanent magnet, the short-distance coefficient is 1, the winding coefficient is increased, the output performance will be improved, the overall copper loss of the winding is low, and the corresponding efficiency and power density will be improved.

[0050] In the present invention, the via holes connected to the effective conductor can be drilled with more holes along the circumferential direction and radial direction of the effective conductor, so as to conduct a larger current.

[0051] In the present invention, the coil group in the stator plate winding is not composed of a single concentric coil, but each conductor is connected to the conductor closest to it, so that the end is relatively short, the loss is reduced, and the output performance is improved. In addition, the space of the stator plate is fully utilized, and the volume of the stator and even the motor is reduced. It has great advantages in occasions with high space requirements.

[0052] It should be noted that the above embodiments can be freely combined as needed. The above are only preferred embodiments of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be regarded as the protection scope of the present invention.

Claims

1. A stator structure based on a disc-type permanent magnet motor winding, characterized in that: include: At least 6-layer or 6N-layer PCB, and Hall sensor; Each layer of the PCB board is provided with: a plurality of groups of outer ends, a winding setting part, and a plurality of groups of inner ends; At least three-phase windings are arranged on each layer of the PCB board, and two wiring terminals are arranged corresponding to each phase of the winding; the wiring terminals are arranged on the outer end; Each phase winding coil is printed and arranged from the corresponding outer end; The winding coils are printed uniformly on the winding arrangement portion along the circumferential direction, and the lengths of the winding coils are printed in parallel along the radial direction, and are arranged in parallel without overlapping; The winding coils of the same phase arranged on each layer of the PCB board are connected through the outer end and the inner end; The Hall sensor is arranged at an angle on the outer end; The layers in the PCB are connected through vias, and the outer end, the inner end, and the winding setting part are a whole and constitute a same layer of the PCB; The conductors constituting the winding coils of the same phase on the same layer of the PCB board are connected in a non-concentric spiral shape, including: In the upper layer of the first phase winding, the current flows in from the first end of the first phase, enters the first effective conductor through the first outer end conductor, flows into the second effective conductor through the first inner end conductor, then leaves the upper layer of the first phase winding through the via hole and enters the lower layer of the first phase winding, flows into the third effective conductor through the second outer end conductor, flows into the fourth effective conductor through the second inner end conductor, then flows into the fifth effective conductor through the third outer end conductor, flows into the sixth effective conductor through the third inner end conductor, flows into the seventh effective conductor through the fourth outer end conductor, enters the eighth effective conductor through the fourth inner end conductor, enters the ninth effective conductor through the fifth outer end conductor, and flows into the tenth effective conductor through the sixth outer end conductor to form the first winding coil.

2. The stator structure based on the disc permanent magnet motor winding according to claim 1 is characterized in that: include: The outer end portions are all arranged circumferentially along the outer diameter of the winding setting portion and are arranged in an arc; the inner end portions are all arranged circumferentially along the inner diameter of the winding setting portion and are arranged in an arc.

3. The stator structure based on the disc permanent magnet motor winding according to claim 2 is characterized in that: include: A plurality of outer end conductors are arranged on each group of the outer end portions, and the number of the outer end conductors in each group is equal; A plurality of inner end conductors are arranged on each group of the inner end portions, and the numbers of the inner end conductors arranged on two adjacent groups of the inner end portions are different.

4. The stator structure based on the disc-type permanent magnet motor winding according to claim 3 is characterized in that: include: Two ends of the outer end conductor are respectively connected to two different conductors on the winding setting part; Both ends of the inner end conductor are respectively connected to the two conductors on the winding setting part.

5. The stator structure based on the disc-type permanent magnet motor winding according to claim 4 is characterized in that: include: The winding setting part of each layer of the PCB board is provided with multiple conductors, one end of each conductor is connected to the outer end conductor, and the other end is connected to the inner end conductor; the multiple conductors are connected to each other through the corresponding multiple outer end conductors and the corresponding multiple inner end conductors to form the winding coil of the same phase.

6. The stator structure based on the disc-type permanent magnet motor winding according to claim 5 is characterized in that: include: The winding coils printed on the winding arrangement portion of each layer of the PCB board are arranged in a staggered manner according to the different phase numbers of the windings.

7. The stator structure based on the disc-type permanent magnet motor winding according to any one of claims 4 to 6, characterized in that: include: The via holes are arranged at the inner diameter and the outer diameter upper edge of the winding arrangement portion, and each via hole is arranged at both ends of the conductor respectively; Used to connect conductors at the same corresponding positions.

8. The stator structure based on the disc-type permanent magnet motor winding according to claim 7 is characterized in that: include: The conductors on the winding arrangement portion on the same layer of the PCB board are connected in parallel and / or in series.

9. The stator structure based on the disc-type permanent magnet motor winding according to claim 8 is characterized in that: include: The PCB board is arranged in a circular shape.

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