A brushless claw pole motor structure

Abstract

This invention provides a brushless claw-pole motor structure, including a housing assembly, a stator assembly, a rotor assembly, two brushless excitation assemblies, a front cover assembly, a rear cover assembly, a fan, and spring wave plates. The stator assembly is housed within the housing assembly, and the stator assembly and rotor assembly are coaxially assembled with a small air gap. The rotor assembly is assembled to the housing assembly via the front and rear cover assemblies. The brushless excitation assemblies are mounted on the front and rear cover assemblies, respectively, and have small gaps between them and the inner and outer claw assemblies. The motor is self-cooled by a fan, and the bearings in the rear cover assembly are axially preloaded by spring wave plates. This invention features a wide speed range and high output power density.

Description

Technical Field

[0001] This invention relates to a brushless claw pole motor structure, belonging to the field of motor design technology. Background Technology

[0002] In recent years, traditional diesel generator power stations have suffered from poor power quality, excessively large and heavy outputs of high-power products, and significant noise and emissions pollution. Therefore, applying high-performance, high-power power take-off (PTO) technology is an effective solution to the problem of mobile power supply.

[0003] High-performance power take-off (PTO) technology using brushless claw pole generators, with its advantages of high power, high reliability, long life, and light size and weight, will gradually replace existing diesel generator power supply systems and brushed generators, becoming the preferred main power supply equipment for special vehicles. It can be widely used in various fields such as combat, command, logistics support, and medical rescue, and has huge application potential, which will surely bring good military and economic benefits.

[0004] Most existing generators are brushed claw pole generators, while brushless claw pole generators are less commonly used. Moreover, the brushless claw pole generators that are used only have a pair of rotors and an excitation assembly. For motors with large radial dimensions, the excessively long radial dimension increases the centrifugal force, making them unsuitable for high-speed motors. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to overcome the shortcomings of the prior art and provide a brushless claw pole motor structure, which has the advantages of light size and weight, high power density, high reliability, wide speed range and low cost.

[0006] The technical solution adopted in this invention is:

[0007] A brushless claw pole motor structure includes a housing assembly, a stator assembly, a rotor assembly, two brushless excitation assemblies, a front cover assembly, a rear cover assembly, a fan, and spring wave plates;

[0008] The housing assembly contains the stator assembly, which is coaxially assembled with the rotor assembly. The rotor assembly is assembled with the housing assembly via the front cover assembly and the rear cover assembly. Two brushless excitation assemblies are mounted on the front cover assembly and the rear cover assembly respectively and connected in series. The fan is mounted on the rotor assembly shaft, and the bearing in the rear cover assembly is axially preloaded by a spring wave plate.

[0009] Furthermore, the rotor assembly is first installed into the front cover assembly via bearings to form the front cover-rotor assembly. Then, the stator assembly is installed into the housing assembly, and the front cover-rotor assembly is installed into the housing assembly and secured with screws. Then, the rear cover assembly is installed into the rotor assembly and housing assembly. Finally, the spring wave plate and fan are installed in sequence.

[0010] Furthermore, the rotor assembly includes an inner claw assembly, an outer claw assembly, and a magnetic shielding block;

[0011] The two inner jaw assemblies are welded together with the two outer jaw assemblies by a block of magnetic shielding. The two inner jaw assemblies are interference-fitted onto the shaft in a back-to-back structure.

[0012] Furthermore, the inner and outer claw components are made of magnetically conductive materials, while the magnetic shielding block is made of non-magnetically conductive 0Cr16Ni14 steel.

[0013] Furthermore, the claw pole angles of the two inner claw assemblies are consistent, and the claw poles of the two outer claw assemblies differ from the claw poles of the inner claw assemblies by 22.5°. The magnetic shielding block is located at the claw tip position of the inner and outer claw assemblies, ensuring that the magnetic shielding block is flush with the claw tip.

[0014] Furthermore, the two brushless excitation components are formed by coil windings wound on an excitation frame, and the excitation frame is made of a magnetically conductive material.

[0015] Furthermore, there is an air gap δ1 between the two brushless excitation components and the inner jaw assembly, and an air gap δ2 between the two components and the outer jaw assembly; there is an air gap δ3 between the stator assembly and the inner jaw assembly.

[0016] Furthermore, when the two brushless excitation components are energized with DC, they provide excitation magnetic fields in opposite directions to the two pairs of claw pole structures; when the rotor rotates, a rotating magnetic field is formed, the stator windings cut the magnetic lines of force, and output three-phase AC power.

[0017] Furthermore, the stator assembly is formed by stacking and welding silicon steel sheets to form a stator core, which has 96 slots and three sets of stator windings are wound on the core.

[0018] Furthermore, of the three sets of stator windings, two sets are main windings with the same winding method and a 30° difference between them, and the two main windings are connected in parallel for output. The third set of windings is the excitation source winding.

[0019] The advantages of this invention compared to the prior art are:

[0020] 1) This invention adopts a brushless claw pole structure, which eliminates the slip ring and brush components in the traditional brushed motor structure, extends the motor maintenance time, and increases the motor power in the same volume.

[0021] 2) This invention employs a two-pair claw pole structure, with the inner and outer claws welded together by a magnetic shielding welding block, which improves the centrifugal deformation problem caused by the excessive length of the claw pole structure under high-speed rotation.

[0022] 3) This invention uses two sets of main windings connected in parallel to reduce the output ripple value.

[0023] 4) This invention uses an independent excitation source winding to isolate the excitation power supply from the motor output, reducing the difficulty of excitation control. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of the present invention;

[0025] Figure 2 This is a schematic diagram of the rotor assembly structure of the present invention;

[0026] Figure 3 A schematic diagram of the unfolded planar portion of the rotor assembly of the present invention;

[0027] Figure 4 This is a schematic diagram of the main winding unwinding method of the present invention;

[0028] Figure 5 This is a schematic diagram of the air gap location in this invention.

[0029] In the diagram: 1-Front end cover assembly, 2-Outer claw assembly, 3-Excitation assembly, 4-Housing assembly, 5-Stator assembly, 6-Inner claw assembly, 7-Magnetic shielding welding block, 8-Rear end cover assembly, 9-Fan, 10-Spring wave plate, 11-Rotor assembly. Detailed Implementation

[0030] like Figure 1 As shown, a brushless claw-pole motor structure includes a housing assembly 4, a stator assembly 5, a rotor assembly 11, two brushless excitation assemblies 3, a front cover assembly 1, a rear cover assembly 8, a fan 9, and spring wave plates 10. The stator assembly 5 is housed within the housing assembly 4 and is coaxially assembled with the rotor assembly 11. The rotor assembly 11 is assembled with the housing assembly 4 via the front cover assembly 1 and the rear cover assembly 8. The two brushless excitation assemblies 3 are respectively mounted on the front cover assembly 1 and the rear cover assembly 8 and connected in series. The fan 9 is mounted on the shaft of the rotor assembly 11, and the bearing in the rear cover assembly 8 is axially preloaded by the spring wave plates 10. The motor is self-cooled by the fan 9. In this structure, the brushless excitation assemblies 3 are directly excited by direct current, eliminating the need for a brush assembly structure. At the same power density, this results in a smaller junction size and longer lifespan compared to traditional brushed motors.

[0031] During assembly, the rotor assembly 11 is first installed into the front cover assembly 1 via bearings, forming the front cover-rotor assembly. Then, the stator assembly 5 is installed into the housing assembly 4, followed by the front cover-rotor assembly into the housing assembly 4, which is then tightened with screws. Next, the rear cover assembly 8 is installed into the rotor assembly 11 and housing assembly 4. Finally, the spring wave plate 10, fan 9, etc., are installed sequentially. The structure of the rotor assembly 11, compared to a single-pole structure of the same size, exhibits less deformation due to centrifugal force, making it suitable for high-speed structures.

[0032] The housing assembly contains the stator assembly, which is coaxially assembled with the rotor assembly and has a small air gap. Specifically, for example... Figure 5 As shown, there is an air gap δ1 between the two brushless excitation components and the inner claw assembly, and an air gap δ2 between the two components and the outer claw assembly; there is an air gap δ3 between the stator assembly and the inner claw assembly. δ1 is the main air gap of the generator, providing a three-phase rotating magnetic field for the stator; δ2 and δ3 are auxiliary air gaps, allowing the two brushless claw pole excitation components to be directly mounted on the front cover assembly and the rear cover assembly, without rotating with the rotor assembly, thus realizing the brushless excitation structure of the motor.

[0033] This invention employs a brushless claw pole structure, eliminating the slip rings and brushes found in traditional brushed motors, thus extending motor maintenance time and increasing motor power within the same volume.

[0034] like Figure 2 As shown, the rotor assembly 11 consists of two inner jaw assemblies 6 and two outer jaw assemblies 2 welded together by 64 magnetic shielding blocks 7. The two inner jaw assemblies 6 are interference-fitted onto the shaft in a back-to-back structure. The inner jaw assemblies 6 and outer jaw assemblies 2 are made of magnetically conductive 10# steel, and the magnetic shielding blocks 7 are made of non-magnetically conductive 0Cr16Ni14 steel.

[0035] like Figure 3 As shown, the claw pole angles of the two inner claw assemblies 6 are the same, and the claw poles of the two outer claw assemblies 2 are 22.5° different from the claw poles of the inner claw assemblies 6. The magnetic shielding welding block 7 is located at the claw tip of the inner claw assembly 6 and the outer claw assembly 2, ensuring that the magnetic shielding welding block 7 is flush with the claw tip.

[0036] The rotor assembly 11 formed by two pairs of claw pole structures avoids the problem of large centrifugal deformation at high speeds caused by the excessive axial length of a single pair of claw pole structures. Therefore, the present invention is suitable for high-speed motors.

[0037] Two brushless excitation components 3 are fixed to the front cover assembly 1 and the rear cover assembly 8 with screws and connected in series. When the excitation coil is energized with DC, it provides excitation magnetic fields in opposite directions to the two pairs of claw pole structures. When the rotor rotates, a rotating magnetic field is formed, the stator winding cuts the magnetic lines of force, and outputs three-phase AC.

[0038] The stator assembly is formed by laminating and welding silicon steel sheets to create the stator core. The stator core has 96 slots and employs three sets of stator windings, two of which are the main windings. The windings are laid in the same manner but differ by 30° from each other. Figure 4 As shown, this invention employs two sets of main windings connected in parallel to reduce high-order harmonics in the output voltage. The third winding is the excitation source winding, which supplies power to the excitation winding independently. This invention uses an independent excitation source winding to isolate the excitation power supply from the motor output, eliminating the influence between the main winding output and the excitation power supply, and reducing the difficulty of excitation control.

[0039] The brushless claw-pole generator of this invention has superior performance compared to other similar products:

[0040]

[0041] The brushless claw pole generator of this invention has a structure of two pairs of rotors and two excitation components, which is suitable for high-speed motors. No relevant literature has been found on this type of motor.

[0042] The parts of this invention not described in detail are well-known to those skilled in the art.

Claims

1. A brushless claw-pole motor structure, characterized by: The shell assembly (4), the stator assembly (5), the rotor assembly (11), two brushless excitation assemblies (3), the front end cover assembly (1), the rear end cover assembly (8), the fan (9), the spring wave piece (10); The stator assembly (5) is coaxially assembled with the rotor assembly (11), the rotor assembly (11) is assembled with the shell assembly (4) through the front end cover assembly (1) and the rear end cover assembly (8), the two brushless excitation assemblies (3) are respectively arranged on the front end cover assembly (1) and the rear end cover assembly (8) and are connected in series, the fan (9) is installed on the shaft of the rotor assembly (11), and the bearing in the rear end cover assembly (8) is axially pre-tightened through the spring wave piece (10); Firstly, the rotor assembly (11) is assembled into the front end cover assembly (1) through the bearing to form a front end cover-rotor assembly, then the stator assembly (5) is assembled into the shell assembly (4), the front end cover-rotor assembly is assembled into the shell assembly (4), the shell assembly (4) is fixed through screw fastening, then the rear end cover assembly (8) is assembled into the rotor assembly (11) and the shell assembly (4), and finally the spring wave piece (10) and the fan (9) are sequentially installed. The rotor assembly (11) comprises the inner claw assembly (6), the outer claw assembly (2) and the magnetic separation block (7). The two inner claw assemblies (6) and the two outer claw assemblies (2) are welded together through the 64 magnetic separation blocks (7), and the two inner claw assemblies (6) are installed on the shaft in a back-to-back structure with interference. The claw pole angles of the two inner claw assemblies (6) are consistent, the claw poles of the two outer claw assemblies (2) are different from the claw poles of the inner claw assemblies (6) by 22.5°, and the magnetic separation blocks (7) are located at claw tip positions of the inner claw assemblies (6) and the outer claw assemblies (2), so that the magnetic separation blocks (7) are flush with the claw tips. The two brushless excitation assemblies (3) are separated from the inner claw assemblies (6) by an air gap δ1 and separated from the outer claw assemblies (2) by an air gap δ2, and the stator assembly (5) is separated from the inner claw assemblies (6) by an air gap δ3. When direct current passes through the two brushless excitation assemblies (3), opposite excitation magnetic fields are provided for the two pairs of claw pole structures, and when the rotor rotates, a rotating magnetic field is formed, the stator winding cuts the magnetic lines, and three-phase alternating current is output. The stator assembly (5) is formed by laminating and welding silicon steel sheets to form a stator core, the stator core has 96 slots, and three sets of stator windings are wound on the stator core. The three sets of stator windings include two sets of main windings and one set of excitation source windings, the two sets of main windings have the same wire laying mode and are different by 30°, and the two sets of main windings are connected in parallel to output.

2. A brushless claw pole motor structure according to claim 1, characterized in that: The inner claw assemblies (6) and the outer claw assemblies (2) are made of magnetic conductive material, and the magnetic separation blocks (7) are made of non-magnetic material 0Cr16Ni14 steel.

3. A brushless claw pole motor structure according to claim 1, characterized in that: The two brushless excitation assemblies (3) are formed by winding coil windings on an excitation framework, and the excitation framework is made of magnetic conductive material.

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