Brushless motor and method of manufacturing the same, apparatus

Abstract

The present disclosure relates to a brushless motor and a manufacturing method and device thereof, wherein the brushless motor comprises: at least one stator core (1) comprising a plurality of tooth groups (11) arranged at intervals along the circumferential direction, the total number of tooth groups (11) being Z; a rotor (2) rotatable relative to the stator core (1), the rotor (2) comprising a magnetic ring (21) with a pole number P, P being an even number; and at least two phase conductors (3) wound on the tooth groups (11) to form coils (31) on the tooth groups (11), the total number of phase conductors (3) being X, each phase conductor (3) having an independent first end and a second end; for the same phase conductor (3), the number of tooth groups (11) spaced between the coils (31) on the adjacent two tooth groups (11) is X-1, and the winding directions of the coils (31) on the adjacent two tooth groups (11) along the circumferential direction of the tooth groups (11) are opposite; wherein Z=P*X.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a brushless motor and a manufacturing method and device thereof. BACKGROUND

[0002] The direct-current brushless motor has the advantages of the traditional direct-current motor, while eliminating the carbon brush and slip ring structure, and can operate at low speed and high power. It not only has small size and light weight, but also has good stability and high efficiency, and therefore is widely used in various fields.

[0003] Although different types of brushless motors can basically meet the use requirements, it is still difficult to achieve a relatively optimal comprehensive performance, mainly in that it is difficult to balance multiple performance indicators such as torque and efficiency, and when selecting the type of motor, only the most important performance indicator can be prioritized according to the use requirements. Therefore, the comprehensive performance of the brushless motor needs to be further improved to better meet the automated driving requirements. SUMMARY

[0004] Some embodiments of the present disclosure provide a brushless motor and a manufacturing method and device thereof, which can improve the comprehensive performance of the brushless motor.

[0005] According to a first aspect of the present disclosure, a brushless motor is provided, comprising:

[0006] at least one stator core, the stator core comprising a plurality of tooth groups arranged at intervals along a circumferential direction thereof, the total number of tooth groups being Z;

[0007] a rotor rotatable relative to the stator core, the rotor comprising a magnetic ring with a pole number P, P being an even number; and

[0008] at least two phase conductors wound on the tooth groups to form coils on the tooth groups, the total number of phase conductors being X, each phase conductor having an independent first end and a second end; for the same phase conductor, the number of tooth groups spaced between the coils on the adjacent two tooth groups is X-1, and the winding directions of the coils on the adjacent two tooth groups along the circumferential direction of the tooth groups are opposite.

[0009] wherein Z=P*X.

[0010] In some embodiments, the tooth group comprises a single tooth, and the conductor is wound on the tooth to form a coil on the tooth; and / or the tooth group comprises at least two teeth arranged at intervals along the circumferential direction of the stator core, and the conductor is wound on the at least two teeth to form coils on the at least two teeth.

[0011] In some embodiments, each phase conductor is configured to be connected to an independent driving signal.

[0012] In some embodiments, in the radial direction of the stator core, the winding directions of each coil formed by the at least two phase conductors are consistent.

[0013] In some embodiments, the starting winding position of each coil formed by the at least two phase conductors is located on the side away from the rotor.

[0014] In some embodiments, the first end and the second end of the at least two phase conductors are led out from the same side of the tooth group in the radial direction of the stator core.

[0015] In some embodiments, all the first ends and the second ends are led out from a plurality of adjacent tooth groups in the circumferential direction of the stator core.

[0016] In some embodiments, the winding direction of the at least two phase conductors from the first end to the same number coil on the tooth group is consistent; or the winding direction of the at least one group of adjacent two phase conductors from the first end to the same number coil on the tooth group is opposite.

[0017] In some embodiments, the at least two phase conductors are sequentially wound from the 1st to the Xth phase in the circumferential direction of the stator core.

[0018] The conductors through which the driving signals are input include the ith phase conductor and the kth phase conductor, and the phase difference between the driving signal of the ith phase conductor and the driving signal of the kth phase conductor is wherein 1≤i

[0019] In the same stator core, the tooth group of the xth phase conductor and the two adjacent tooth groups on both sides have a gap at the closest position, and the gap has a center position in the circumferential direction of the stator core; among all the gaps formed by the Z tooth groups, the central angle corresponding to the circle center of the arc between the center position of the xth phase conductor and the adjacent center position in the circumferential direction of the stator core is β x , and β x The corresponding sector includes at least part of the tooth group of the xth phase conductor.

[0020] In some embodiments, a plurality of stator cores are arranged in the axial direction, and each stator core includes at least one phase conductor, and the tooth groups of the plurality of stator cores are arranged staggered in the circumferential direction of the stator core.

[0021] In some embodiments, the driving signal strength input by the conductors of all phases is consistent within the entire target speed range of the rotor.

[0022] In some embodiments,

[0023] In the case where the target torque of the rotor is higher than the first preset torque, the driving signal strength input by the conductors of each phase is consistent;

[0024] In the case where the target torque of the rotor is not higher than the first preset torque, the driving signal input by the conductors of part of the phases has a preset strength, and the driving signal input by the conductors of the remaining phases is lower than the preset strength or not driven.

[0025] In some embodiments, the brushless motor has a first working mode in which each phase conductor is energized all the time, and the driving signals between adjacent phase conductors have a phase difference.

[0026] In some embodiments, the brushless motor has a second working mode in which each phase conductor is energized intermittently, and the driving signals between adjacent phase conductors have a phase difference.

[0027] In some embodiments, the magnetic ring is sleeved outside the stator core.

[0028] In some embodiments, the stator core is annular and sleeved outside the magnetic ring.

[0029] In some embodiments, the stator core and the magnetic ring are arranged in axial superposition, and the magnetic ring at least partially covers the coil in the radial direction of the stator core.

[0030] In some embodiments, the stator core is provided on both sides of the magnetic ring in the axial direction; and / or

[0031] The magnetic ring is provided on both sides of the stator core in the axial direction.

[0032] According to a second aspect of the present disclosure, a device is provided, comprising the brushless motor of the above-mentioned embodiments.

[0033] According to a third aspect of the present disclosure, a manufacturing method of the brushless motor is provided, comprising:

[0034] The wire providing step provides a wire;

[0035] The winding step winds the wire on the tooth groups in different phase sequence orders until a coil is formed on each tooth group; in the same phase corresponding to all the coils, the number of tooth groups between the coils on the adjacent two tooth groups is X-1, and the winding direction of the coils on the adjacent two tooth groups is opposite in the circumferential direction of the tooth groups;

[0036] The wire breaking step breaks the wire at the connection of adjacent phase sequences, so that the total number of phases of the wire is X, and each phase conductor has an independent first end and a second end.

[0037] Based on the above technical solutions, this disclosure has at least the following beneficial effects: (1) The number of phases of the motor is increased, which can achieve a larger torque and can be applied to high-power products; (2) Each phase conductor is independent and can be driven independently. Each phase conductor can be energized at all times to make the rotor rotate, which improves the utilization rate of the winding and stator core and increases the ultimate working efficiency; the energization of each phase conductor does not need to be frequently switched, which can improve working stability and reduce working noise. The force is uniform during steady-state driving and it is not easy to generate vibration inside the stator core, which can improve the working stability and overall life of the motor; (3) The number of magnetic poles of the magnetic ring can be reduced. For the same speed and power, it is necessary to switch the energization twice to complete the rotation of a pair of magnetic poles, which can reduce the driving frequency and reduce the driving difficulty; (4) The conductors of the same phase are alternately wound, the winding method is simple, and the degree of automation of winding can be improved. Attached Figure Description

[0038] The accompanying drawings, which are included to provide a further understanding of this disclosure and form part of this application, illustrate exemplary embodiments of this disclosure and are used to explain this disclosure, but do not constitute an undue limitation of this disclosure. In the drawings:

[0039] Figure 1 This is a schematic diagram of the engagement between the stator core and the magnetic ring in the first embodiment of the brushless motor disclosed herein;

[0040] Figure 2 This is a schematic diagram of the structure of two-phase wires wound around the stator core in the first embodiment of the brushless motor disclosed herein;

[0041] Figure 3 This is a schematic diagram illustrating the working principle of the two-phase brushless motor disclosed in this paper.

[0042] Figure 4 This is a schematic diagram of the engagement between the stator core and the magnetic ring in the second embodiment of the brushless motor disclosed herein;

[0043] Figure 5 This is a schematic diagram of the structure of two-phase wires wound around the stator core in the second embodiment of the brushless motor disclosed herein;

[0044] Figure 6 This is a schematic diagram showing that both phase conductors of the brushless motor disclosed herein are supplied with a continuous sinusoidal drive signal;

[0045] Figure 7 This is a schematic diagram showing that discontinuous sinusoidal drive signals are passed through both phase conductors of the brushless motor disclosed herein.

[0046] Figure 8 This is a schematic diagram showing that square wave drive signals are passed through both phase wires of the brushless motor disclosed in this invention.

[0047] Figure 9Figure 3 is a schematic view of the cooperation between the stator core and the magnetic ring in the third embodiment of the brushless motor of the present disclosure;

[0048] Figure 10 Figure 4 is a schematic view of the structure of the winding of the three-phase conductors on the stator core in the third embodiment of the brushless motor of the present disclosure;

[0049] Figure 11 Figure 5 is a schematic view of the conductors in the three-phase brushless motor of the present disclosure being connected to a continuous sinusoidal wave driving signal;

[0050] Figure 12 Figure 6 is a schematic view of the conductors in the three-phase brushless motor of the present disclosure being connected to a square wave driving signal;

[0051] Figure 13 Figure 7 is a schematic view of the cooperation between the stator core and the magnetic ring in the fourth embodiment of the brushless motor of the present disclosure;

[0052] Figure 14 Figure 8 is a schematic view of the two-phase conductors in the fourth embodiment being connected to a continuous sinusoidal wave driving signal;

[0053] Figure 15 Figure 9 is a schematic view of the structure of the winding of the two-phase conductors on the stator core in the fifth embodiment of the brushless motor of the present disclosure;

[0054] Figure 16 Figure 10 is a schematic view of the structure of the magnetic ring in the fifth embodiment of the brushless motor of the present disclosure;

[0055] Figure 17 Figure 11 is a schematic view of the cooperation between the stator core and the rotor in the fifth embodiment of the brushless motor of the present disclosure;

[0056] Figure 18 Figure 12 is a schematic view of the cooperation between the stator core and the rotor in a variant of the fifth embodiment of the brushless motor of the present disclosure;

[0057] Figure 19 Figure 13 is a schematic view of the cooperation between the stator core and the rotor in another variant of the fifth embodiment of the brushless motor of the present disclosure;

[0058] Figure 20 Figure 14 is a sectional view of the sixth embodiment of the brushless motor of the present disclosure;

[0059] Figure 21 Figure 15 is a schematic view of the structure of the winding of the X1 -phase conductors on one of the stator cores in the sixth embodiment of the brushless motor of the present disclosure;

[0060] Figure 22 Figure 16 is a schematic view of the structure of the winding of the X2 -phase conductors on the other stator core in the sixth embodiment of the brushless motor of the present disclosure;

[0061] Figure 23 Figure 17 is a schematic view of the structure of the axial superposition of the two stator cores in the sixth embodiment of the brushless motor of the present disclosure.

[0062] BRIEF DESCRIPTION OF REFERENCE NUMERALS

[0063] 1. Stator core; 11, tooth group; 11', tooth; 111, neck portion; 112, shoe portion; 12, yoke portion;

[0064] 2. Rotor; 21, magnetic ring; 22, rotating shaft;

[0065] 3. Wire; 31, coil; 32, connecting section;

[0066] 4. Connecting shaft. DETAILED DESCRIPTION

[0067] Various exemplary embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings. The description of the exemplary embodiments is merely illustrative in nature and is in no way intended to limit the disclosure, its application or uses, except as described by the appended claims. The disclosure can be implemented in numerous different forms, as will be apparent to one of ordinary skill in the art. The embodiments provided are in order to convey the subtleties of the present disclosure and not to limit its scope as can be in accordance to the patent laws. It should be noted that the relative arrangement of the components and steps illustrated in these embodiments, the components of the materials, numerical expressions, and numerical values set forth in these embodiments are to be interpreted as illustrative only, and not as a limitation of the disclosure unless otherwise specifically indicated.

[0068] The terms "first", "second", and similar terms used in the present disclosure do not denote any order, quantity, or importance, but are used to distinguish different parts. The terms "include", "comprise", and similar terms mean that the elements before the terms encompass the elements listed after the terms, and do not exclude the possibility of also encompassing other elements. "Up", "down", "left", "right", and the like are used only to indicate relative positional relationships, and when the absolute positions of the described objects are changed, the relative positional relationships can also be changed accordingly.

[0069] In the present disclosure, when it is described that a certain device is located between a first device and a second device, there can be an intervening device between the certain device and the first device or the second device, or there can be no intervening device. When it is described that a certain device is connected to other devices, the certain device can be directly connected to the other devices without an intervening device, or can not be directly connected to the other devices with an intervening device.

[0070] All terms used in the present disclosure, including technical or scientific terms, have the same meanings as those understood by those skilled in the art to which the present disclosure pertains, unless otherwise specifically defined. It should also be understood that terms such as those defined in a generally used dictionary should be interpreted as having meanings consistent with the meanings in the context of the relevant technology, and should not be interpreted in an idealized or extremely formalized sense, unless otherwise clearly defined herein.

[0071] Techniques, methods, and apparatus known to those of ordinary skill in the relevant art(s) can not be discussed in any detail since the techniques, methods, and apparatus should be readily understood by those of ordinary skill in the art.

[0072] The present disclosure provides an electric machine, hereinafter referred to as "electric machine", which can be an electric motor for converting electric energy into mechanical energy, or a generator for converting mechanical energy into electric energy. In some embodiments, as Figures 1 to 23 such an electric machine comprises:

[0073] at least one stator core 1 comprising a plurality of tooth groups 11 arranged along a circumferential direction of the stator core 1, the total number of tooth groups 11 being Z;

[0074] a rotor 2 rotatable relative to the stator core 1, the rotor 2 comprising a plurality of magnetic rings 21 having a pole number P, P being an even number; and

[0075] at least two phase conductors 3 wound on the tooth groups 11 to form coils 31 on the tooth groups 11, the total number of phase conductors 3 being X, each phase conductor 3 having an independent first end and a second end; for the same phase conductor 3, the number of tooth groups 11 between the coils 31 on two adjacent tooth groups 11 is X-1, and the winding direction of the coils 31 on the two adjacent tooth groups 11 is opposite along the circumferential direction of the tooth groups 11;

[0076] wherein Z = P*X.

[0077] In this embodiment, the stator core 1 can be provided with one or more than two, each stator core 1 can comprise a yoke 12 and a plurality of tooth groups 11, the plurality of tooth groups 11 being connected to the yoke 12. For example, the yoke 12 is annular, such as a circular ring, as shown in Figure 1 the plurality of tooth groups 11 are connected to the outer side wall of the yoke 12; as shown in Figure 4 the plurality of tooth groups 11 are connected to the inner side wall of the yoke 12; as shown in Figure 15 the plurality of tooth groups 11 are connected to the end of the yoke 12 along the axial direction.

[0078] The total number of tooth groups 11 is Z, if the stator core 1 is provided with more than two, the total number of tooth groups 11 is the number of tooth groups 11 in all stator cores 1. Each tooth group 11 can comprise one or at least two teeth 11', and each tooth group 11 is defined as a group of teeth 11' in each stator core 1 according to the winding grouping.

[0079] The rotor 2 and the stator core 1 can be coaxially arranged and rotatable relative to the stator core 1, referring to Figures 17 to 19 the rotor 2 can comprise a plurality of magnetic rings 21 and a rotating shaft 22 connected to the plurality of magnetic rings 21 for outputting the power of the electric machine, the pole number P of the plurality of magnetic rings 21 being an even number, P≥2, for example, Figure 1The number of poles P of the middle magnetic ring 21 is 4, that is, it has two pairs of magnetic poles, which are alternately arranged along the circumference of the stator core 1 in an NSNS pattern. Alternatively, the number of poles P can also be 6, 8, ... For different structural forms, such as Figure 1 As shown, the magnetic ring 21 is located outside the stator core 1; as Figure 4 As shown, the stator core 1 is annular, and the magnetic ring 21 is disposed inside the stator core 1; Figure 16 As shown, the magnetic ring 21 and the stator core 1 are stacked together along the axial direction.

[0080] At least two phase conductors 3 are wound around the tooth group 11 to form coils 31 on the tooth group 11. The total number of phases of the conductors 3 is X, that is, after the stator core 1 is wound, there are X independent conductors 3. Each phase conductor 3 has an independent first end and a second end. For example, the first end is the input end and the second end is the output end, or vice versa. For each phase conductor 3, a coil 31 is formed on the corresponding tooth group 11. The coils 31 on two adjacent tooth groups 11 are connected by a connecting section 32. This connecting section 32 can cross the tooth group 11 corresponding to other phase conductors 3 from the end face of the stator core 1.

[0081] Each phase conductor 3 is represented by X1, X2, ..., and the number of tooth groups 11 between the coils 31 on two adjacent tooth groups 11 is X-1. For example, Figure 1 and Figure 2 For each phase conductor 3, the conductor is wound once every time the tooth group 11 is skipped during winding. Figure 9 and Figure 10 For each phase conductor 3, the conductor is wound once every two adjacent tooth groups 11 during winding.

[0082] Regarding parameter selection, the number of poles P of the magnetic ring 21 mainly depends on the design power of the motor. The higher the power, the more poles are needed, and the more poles, the greater the torque. The number of poles P is also related to the motor configuration; there are different considerations when determining the magnetic poles for inner and outer rotors. However, the ultimate goal is to maximize the number and density of windings within a reasonable motor space to achieve the maximum output power of the motor. In addition, increasing power can also increase the axial thickness of the magnets and stator core 1 or the magnetic force of the magnet material. For the number of phases X, a two-phase motor is generally chosen to simplify the structure and reduce the difficulty of driving. However, in some applications, the torque can be increased by increasing the number of phases X. For example, in electric bicycles, it is necessary to increase the motor torque within a reasonable size range. Using three-phase windings can effectively increase the output torque of the motor and also achieve high torque output at low speeds.

[0083] Next, the working principle of this type of motor will be explained, such as... Figure 3As shown, for the convenience of understanding, the magnetic ring 21 and the plurality of teeth 11' are shown in a straight line expanded form. Taking a two-phase motor as an example, the coils 31 on the adjacent two tooth groups 11 have opposite winding directions along the circumferential direction of the tooth group 11. Thus, in the process of rotating the rotor 2 by energizing the conductors 3, if the coils 31 on a tooth 11' of the A-phase conductor 3 generate an N-pole magnetic field, and the tooth 11' is aligned with the critical point O of the magnetic pole S, at this time, the two teeth 11' adjacent to it are wound around the B-phase conductor 3, and the two coils 31 generate N and S magnetic fields respectively due to the opposite winding directions, for example, the left side is an N-pole magnetic field attracting the magnetic pole S, and the right side is an S-pole magnetic field repelling the magnetic pole S. The opposite magnetic fields generated by the adjacent phase conductors 3 generate thrust and pull respectively, which can generate a large force to make the tooth group 11 corresponding to the A-phase conductor cross the critical point O, so that the magnetic ring 21 moves in the direction of the arrow.

[0084] The motor of this embodiment has at least one of the following advantages:

[0085] (1) Compared with a single-phase motor, a single-phase motor is difficult to achieve a large torque, and is only suitable for small-power products such as handheld fans, computer cooling fans, and small table fans, because it needs to rely on the rotational inertia of the rotor to pass through the critical point of the alignment of the rotor magnetic pole and the tooth. However, these products will have obvious electromagnetic noise when in use.

[0086] The motor of the present disclosure increases the number of phases, and when the tooth group 11 corresponding to a certain phase conductor 3 reaches the critical point O, the coils 31 located on both sides of the tooth group 11 in the remaining phase conductors 3 can generate opposite magnetic field directions due to the opposite winding directions, and can generate thrust and pull on the tooth group 11 reaching the critical point O, respectively, which can generate a large force to make the tooth group 11 corresponding to the A-phase conductor cross the critical point O. Therefore, such a motor can achieve a large torque and can be applied to high-power products.

[0087] (2) Compared with a traditional three-phase motor, the traditional three-phase motor is driven by cross-supplying UVW three-phase windings. To achieve stable load rotation, the three-phase windings need to be switched on in six regular ways. During the driving and energizing process, one winding is always not energized and does not do work, so that the maximum utilization rate of the winding and the core is only about 66%. The combination and working principle of such a three-phase motor result in a relatively low limit efficiency, and the frequent switching of energization will bring about a relatively large working noise. Moreover, the winding is energized intermittently, and the law of the reaction force of the magnetic pull of the core will cause the core to vibrate, and the motor is prone to high-frequency vibration during high-speed switching, which is poor in working stability and affects the service life of the bearing.

[0088] The independent power supply driving of each phase wire 3 in the motor of the present disclosure can be realized, and each phase wire 3 can be energized in the full period to rotate the rotor 2, the utilization rate of the winding and the stator core can reach 100%, thereby increasing the limit working efficiency of the motor. Moreover, the energization of each phase wire 3 does not need to be frequently switched, the working stability of the motor is improved, and the working noise is reduced. In addition, the stable and continuous energization in the driving process can make the law of the reaction force of the stator core 1 to the magnetic pull generated by the stator core 1 consistent with the rotation direction, the force is uniform in the steady-state driving, and the shaking in the stator core 1 is not easy to occur, thereby improving the working stability and overall life of the motor.

[0089] (3) Compared with the traditional three-phase motor, the basic formula of the traditional three-phase motor design is: motor teeth number=(magnetic pole number / 2)*3, that is, the tooth number corresponding to the 8-pole magnetic ring is (8 / 2)*3=12 teeth.

[0090] In the motor of the present disclosure, it is assumed that there is one tooth 11' in each tooth group 11, and the total number of teeth 11' is Z, Z=P*X. For a two-phase motor, if the stator core 1 also has 12 teeth 11', the magnetic pole number P=12 / 2=6. By comparison, in the case of equal tooth number, the motor of the present disclosure can reduce the magnetic pole number P of the magnetic ring 21. For the same speed and power, two switching energizations are needed to complete the rotation of a pair of magnetic poles, which can reduce the driving frequency and thus reduce the driving difficulty.

[0091] (4) Compared with the traditional three-phase motor, the stator assembly of the traditional three-phase motor taken from the automatic production line has two wire heads in and out, and the wires are irregular and messy. The production process needs a flexible assembly station. The wires are cut by hand first, and then six wire heads are found. Finally, three wire heads of UVW are reserved. In this kind of stator assembly, there are many crossed wires, and the automatic winding is difficult.

[0092] In the motor of the present disclosure, the wires 3 of the same phase are alternately wound, the winding method is simple, and since the X-phase wires 3 are independent of each other, the X-phase wires 3 can be automatically wound to have first ends and second ends respectively after winding, the number of wires is reduced, and manual trimming is not needed to enter the next process, thereby improving the degree of automation of winding and improving the production efficiency and winding success rate.

[0093] In this embodiment, the forward and reverse rotation of the motor can be realized by adjusting the order of driving the X-phase wires 3. The driving signals of the 1-X phase wires 3 are sequentially input, and the forward rotation of the motor can be realized (the forward rotation can be defined as counterclockwise or clockwise); the driving signals of the X-1 phase wires 3 are sequentially input, and the reverse rotation of the motor can be realized.

[0094] For example, for a two-phase motor, if the motor rotates forward when the driving signal is input in the order of X1 first and X2 second, the motor rotates reversely when the driving signal is input in the order of X2 first and X1 second.

[0095] For example, for a three-phase motor, if the motor rotates forward when the driving signal is input in the order of X1-X2-X3, the motor rotates reversely when the driving signal is input in the order of X3-X2-X1.

[0096] In some embodiments, as shown in Figs. 1 and 2, the tooth group 11 includes a single tooth 11', and the wire 3 is wound around the tooth 11' to form a coil 31 on the tooth 11'. Figure 2 and Figure 5 For example, all the tooth groups 11 in the stator core 1 include only a single tooth 11', as shown in Figs. 1 and 2, the tooth 11' includes a neck portion 111 and a shoe portion 112, and the cross section of the neck portion 111 can be circular, elliptical, triangular, rectangular or other polygonal, etc., the shoe portion 112 is connected to the neck portion 111 and can be circular arc-shaped, the shoe portion 112 is connected to the radial end of the neck portion 111, such as the radial inner end or the radial outer end, the coil 31 is wound around the neck portion 111, and the radial ends are blocked and positioned by the yoke portion 12 and the shoe portion 112, respectively.

[0097] For example, all the tooth groups 11 in the stator core 1 include only a single tooth 11', as shown in Figs. 1 and 2, the tooth 11' includes a neck portion 111 and a shoe portion 112, and the cross section of the neck portion 111 can be circular, elliptical, triangular, rectangular or other polygonal, etc., the shoe portion 112 is connected to the neck portion 111 and can be circular arc-shaped, the shoe portion 112 is connected to the radial end of the neck portion 111, such as the radial inner end or the radial outer end, the coil 31 is wound around the neck portion 111, and the radial ends are blocked and positioned by the yoke portion 12 and the shoe portion 112, respectively. Figure 2

[0098] As shown in Figs. 1 and 2, all the teeth 11' are the same in shape and size, and are spaced apart and uniformly distributed along the circumferential direction of the stator core 1; as shown in Figs. 3 and 4, the sizes of the teeth 11' corresponding to different phase wires 3 are different, i.e., the circumferential coverage angles are different. Figure 2 Figure 13

[0099] This structure is relatively simple to wind, easy to control the tightness of winding, and has relatively low requirements on winding process.

[0100] In some embodiments, the tooth group 11 includes at least two teeth 11', the at least two teeth 11' are spaced apart along the circumferential direction of the stator core 1, and the wire 3 is wound around the at least two teeth 11' to form a coil 31 on the at least two teeth 11'. Specifically, all the teeth 11' in the tooth group 11 are wound with the same phase wire 3 as a whole, and a coil 31 is formed on the tooth group 11.

[0101] Generally, in order to increase the motor torque, the arc length of the shoe portion 112 can be increased, but the coil 31 is wound around the neck portion 111 and can only cover the position where the neck portion 111 is located, and cannot utilize the space between the neck portions 111 of adjacent teeth 11'. This embodiment can make the coil 31 fully cover the space between adjacent tooth groups 11 in the circumferential direction of the stator core 1 by winding the coil 31 on the at least two teeth 11', thereby improving the magnetic flux strength and being beneficial to increasing the motor torque. ​​​

[0102] Optionally, some tooth groups 11 in the stator core 1 may include only a single tooth 11', while the remaining tooth groups 11 may include at least two teeth 11'. This structure allows for flexible configuration according to the performance requirements of the motor.

[0103] In some embodiments, each phase conductor 3 is configured to receive an independent drive signal. Thus, the drive signals received by all phase conductors 3 are independent of each other. For example, the drive signal can be a continuous sine wave, an intermittent sine wave, or a square wave, etc. The commutation of the drive signal causes the magnetic force generated by the coil 31 to commutate.

[0104] In this embodiment, the drive signals supplied to each phase conductor 3 of the motor are independent of each other, requiring only a certain phase difference between them. This allows each phase conductor 3 to be energized at all times, enabling the rotor 2 to rotate. The utilization rate of the windings and stator core can reach 100%, thereby increasing the ultimate operating efficiency of the motor. Moreover, the energization of each phase conductor 3 does not require frequent switching, reducing operating noise. In addition, the stable and continuous energization during the drive process ensures that the reaction force on the stator core 1 when magnetic pull is generated is consistent with the direction of rotation. During steady-state drive, the force is uniform, reducing the likelihood of vibration within the stator core 1, thus improving the motor's operating stability and overall lifespan.

[0105] In some embodiments, the winding direction of each coil 31 formed by at least two phase conductors 3 is consistent in the radial direction of the stator core 1. For example, as... Figure 2 As shown, all coils 31 are wound radially from the inside out. Alternatively, all coils 31 can be wound radially from the outside in.

[0106] The winding method in this embodiment does not require consideration of the winding form of a specific phase conductor 3, and adopts a uniform winding direction in the radial direction, which is beneficial to improving the efficiency of automated winding.

[0107] In some embodiments, the initial winding position of each coil 31 formed by at least two phase conductors 3 is located on the side away from the rotor 2. For example... Figure 2 As shown, for an external rotor motor, the magnetic ring 21 is sleeved outside the stator core 1, and the starting winding position of each coil 31 is located on the radial inner side; in other structural forms, the stator core 1 is annular, the magnetic ring 21 is located inside the stator core 1, and the starting winding position of each coil 31 is located on the radial outer side.

[0108] This embodiment takes into account that the rotor side is equipped with a magnetic ring 21 and other components such as Hall effect sensors, so that the starting winding position is located on the side away from the rotor 2, in order to avoid the wiring affecting the moving parts.

[0109] In some embodiments, in the radial direction of the stator core 1, the first ends and the second ends of the at least two phase conductors 3 are led out from the same side of the tooth group 11. For example, all the first ends and the second ends can be led out from the radially outer side or the radially inner side of the stator core 1.

[0110] In addition, the first ends and the second ends are led out from the tooth slots formed between adjacent tooth groups 11.

[0111] This embodiment facilitates leading the first ends and the second ends of the phase conductors 3 to the electrical interface of the motor, and can make the arrangement of the outgoing lines of the stator core 1 in the motor more orderly.

[0112] In some embodiments, in the circumferential direction of the stator core 1, all the first ends and the second ends are led out from a plurality of adjacent tooth groups 11.

[0113] Figure 2 For the stator core 1 of a two-phase motor, the first ends of the conductors 3 are the input ends, and the second ends are the output ends, the two input ends are X1-IN and X2-IN respectively, and the two output ends are X1-OUT and X2-OUT respectively, the two input ends and the two output ends are led out from four adjacent tooth groups 11, for example, the leading order in the circumferential direction is X2-IN, X1-IN, X2-OUT, and X1-OUT respectively.

[0114] Figure 10 For the stator core 1 of a three-phase motor, the first ends of the conductors 3 are the input ends, and the second ends are the output ends, the three input ends are X1-IN, X2-IN, and X3-IN respectively, and the three output ends are X1-OUT, X2-OUT, and X3-OUT respectively, the three input ends and the three output ends are led out from six adjacent tooth groups 11, for example, the leading order in the circumferential direction is X3-IN, X2-IN, X1-IN, X3-OUT, X2-OUT, and X1-OUT respectively.

[0115] In this embodiment, all the first ends and the second ends are distributed in a relatively close area, which is easier to control the layout positions of the multiple outgoing lines in automated winding, and facilitates leading the multiple outgoing lines to the electrical interface of the motor in an orderly manner, which is conducive to batch production.

[0116] In some embodiments, the at least two phase conductors 3 are consistent in the winding direction of the coils 31 of the same serial number along the tooth group 11 from the first end.

[0117] Taking a two-phase motor as an example, Figure 2The schematic diagram of the two-phase motor is shown in the figure, the first end is the input end, the second end is the output end, the two input ends are X1-IN and X2-IN respectively, the two output ends are X1-OUT and X2-OUT respectively, the number of tooth groups 11 is 8, the X1 phase conductor 3 is wound around four tooth groups 11, and the sequence numbers are 1, 2, 3 and 4, and the X2 phase conductor 3 is wound around four tooth groups 11, and the sequence numbers are 1, 2, 3 and 4. Among them, the winding directions of the X1 and X2 phase conductors 3 on the tooth groups 11 with the same number are consistent, the winding directions of the X1 and X2 phase conductors 3 on the tooth groups 11 with the same number are consistent, the winding directions of the X1 and X2 phase conductors 3 on the tooth groups 11 with the same number are consistent, and the winding directions of the X1 and X2 phase conductors 3 on the tooth groups 11 with the same number are consistent.

[0118] Therefore, X1-IN and X2-IN are both led out from the tooth slots of the adjacent tooth groups 11 on the same side of the stator core 1 in the circumferential direction, that is, from the adjacent tooth slots; X1-OUT and X2-OUT are also both led out from the tooth slots of the adjacent tooth groups 11 on the same side of the stator core 1 in the circumferential direction, that is, from the adjacent tooth slots. Among them, X1-IN and X2-OUT are led out from the same tooth slot.

[0119] This embodiment makes the winding rules of at least two phase conductors 3 consistent, which is equivalent to copying the winding mode of a single-phase conductor 3, so that the winding mode can be simplified, thereby improving the efficiency of automatic winding.

[0120] In other embodiments, at least one set of two adjacent phase conductors 3 has opposite winding directions along the circumferential direction of the tooth group 11 from the coil 31 with the same sequence number from the first end.

[0121] Taking a two-phase motor as an example, on the basis of Figure 2 If the winding directions of X1 and X2 are opposite, X1-IN and X2-IN need to be led out from the tooth slots of the adjacent tooth groups 11 on different sides of the stator core 1 in the circumferential direction, that is, the tooth slots led out by X1-IN and X2-IN are separated by one tooth slot; X1-OUT and X2-OUT also need to be led out from the tooth slots of the adjacent tooth groups 11 on different sides of the stator core 1 in the circumferential direction, that is, from the same tooth slot.

[0122] In the control mode of alternating current, it is necessary to short-circuit the two output ends X1-OUT and X2-OUT in order to be connected with the three half-bridge drive circuits on the circuit board. This winding mode can lead out the two output ends from the same tooth slot, which is convenient for short-circuiting and can better adapt to the layout of the circuit board under the alternating current control mode.

[0123] In some embodiments, at least two phase conductors 3 are sequentially wound along the circumferential direction of the stator core 1 from the first to the Xth phase; the conductors 3 through which the driving signals are input include the ith phase conductor 3 and the kth phase conductor 3, and the phase difference between the driving signals of the ith phase conductor 3 and the kth phase conductor 3 is Wherein, 1≤i

[0124] In the stator core 1, the tooth group 11 of the xth phase conductor 3 and the tooth groups 11 adjacent to the two sides thereof have gaps at the closest positions, and the gaps have a center position in the circumferential direction of the stator core 1; among all the gaps formed by the Z tooth groups 11, the central angle of the circle corresponding to the circular arc between the center position of the xth phase conductor 3 and the center position adjacent to the center position in the circumferential direction of the stator core 1 is β x , and β x corresponds to a sector including at least part of the tooth group 11 of the xth phase conductor 3. Optionally, β x ranges from 1° to 180°.

[0125] Specifically, as Figures 1 to 18 , the stator core 1 is only one, the winding sequence of the at least two phase conductors 3 is 1, … x …, X, 1 < x < X, and the two phase conductors 3 into which the driving signals are input can be adjacent or not adjacent. The tooth group 11 of the xth phase conductor 3 and the tooth groups 11 adjacent to the two sides thereof have gaps at the closest positions, for example, the tooth group 11 only includes a single tooth 11’, the tooth 11’ includes a neck portion 111 and a shoe portion 112, the shoe portion 112 is connected to the radial end of the neck portion 111 to form a T-shaped structure, and the gaps are formed between the shoe portions 112 of the adjacent teeth 11’. The β x corresponding sector only includes one tooth group 11 where the xth phase conductor 3 is located.

[0126] θ ik is the phase difference of the program driving, and within the degree, the control of the driving program commutation will make the magnetic force generated by the coil 31 commutate, and β x corresponds to the phase difference when the program driving, that is, it can ensure that when the program driving signal commutates, the corresponding rotor magnetic field is also just at the commutation position.

[0127] For a two-phase motor, i = 1, k = 2, θ ik = θ 12 is the phase difference of the X1 phase and X2 phase driving signals,

[0128] For a three-phase motor, the following three value conditions can exist:

[0129] i = 1, k = 2, θ ik = θ 12 is the phase difference of the X1 phase and X2 phase driving signals,

[0130] i = 2, k = 3, θ ik = θ 23 is the phase difference of the X2 phase and X3 phase driving signals,

[0131] i = 1, k = 3, θ ik = θ13 The phase difference of the driving signals of the X1 phase and the X3 phase is that the two phases of the driving signals are not adjacent,

[0132] The embodiment can calculate the phase difference between the driving signals of different phases according to the structural parameters of the magnetic ring 21 and the stator core 1, thereby accurately and stably controlling the rotation process of the motor.

[0133] In some embodiments, as shown in Figures 20 to 23 The stator core 1 is arranged in multiple along the axial direction, and each stator core 1 includes at least one phase conductor 3. In the circumferential direction of the stator core 1, the tooth groups 11 of the multiple stator cores 1 are arranged staggered.

[0134] The number of tooth groups 11 in the multiple stator cores 1 can be the same or different. In this structure, the total number of all tooth groups 11 in all stator cores 1 is Z, and the total number of all conductors 3 is X, and Z = P * X. If the multiple stator cores 1 are projected in the reference plane perpendicular to the axis, it is equivalent to that a single stator core 1 is provided with Z tooth groups 11 and X phase conductors 3. The thickness of the magnetic ring 21 can be consistent with the sum of the axial dimensions of the multiple stator cores 1. There is a gap between adjacent stator cores 1 to accommodate the conductors 3 wound on the adjacent stator cores 1. In order to ensure insulation, the conductors 3 on the adjacent stator cores 1 do not contact.

[0135] For example, the stator core 1 is provided with two, and each stator core 1 is wound with a phase conductor 3, and the winding direction of the adjacent tooth groups 11 in the same stator core 1 is opposite, which is used as a two-phase motor; or the stator core 1 is provided with three, and each stator core 1 is wound with a phase conductor 3, which is used as a three-phase motor; or the stator core 1 is provided with two, and one stator core 1 is wound with a phase conductor 3, and the other stator core 1 is wound with two phase conductors 3, which is used as a three-phase motor.

[0136] As shown in Figure 20 The stator core 1 is arranged in two along the axial direction. In order to facilitate installation and ensure the coaxiality of the two stator cores 1, the connecting shaft 4 passes through the central through hole of the two stator cores 1.

[0137] Figure 21 It is a schematic view of winding X1 phase conductors 3 on one of the stator cores 1. In this stator core 1, the winding directions of the coils 31 on the adjacent two tooth groups 11 are opposite, and X1-IN and X1-OUT are led out from the adjacent two tooth groups 11.

[0138] Figure 22This is a schematic diagram of the X2 phase conductor 3 wound on another stator core 1. In this stator core 1, the coils 31 on two adjacent tooth groups 11 have opposite winding directions along the circumference of the tooth group 11. X2-IN and X2-OUT are led out from the two adjacent tooth groups 11.

[0139] Figure 23 This is a schematic diagram of two stator cores 1 stacked axially. The axial length of the magnetic ring 21 can cover the two stator cores 1. The tooth sets 11 of the two stator cores 1 are staggered in their circumferential direction. Specifically, each tooth set 11 has one tooth 11'. Projecting the two stator cores 1 axially onto the same plane, in the circumferential direction of the stator core 1, the necks 111 of the two adjacent teeth 11' and the coils wound on them are completely staggered. The shoe portions 112 of the two adjacent teeth 11' have overlapping portions in the circumferential direction. X1-IN, X2-IN, X1-OUT, and X2-OUT are led out from the four adjacent teeth 11' on the two stator cores 1.

[0140] This type of motor still satisfies Z = P * X. For example, the number of poles of the magnetic ring 21 is P = 8, the number of phases of the conductor 3 is X = 2, the number of tooth groups 11 of each stator core 1 is 8, and the total number of tooth groups 11 of the two stator cores 1 is Z = 16.

[0141] For this type of motor, when determining β x At this time, the gap is formed in two adjacent tooth groups 11 in the same stator core 1. Among all the gaps formed by the Z tooth groups 11, the central angle corresponding to the arc between the center position of the x-th phase conductor 3 and the adjacent center position in the circumferential direction of the stator core 1 is β. x , used to form β x The two gaps are located in the two stator cores 1 respectively. Furthermore, β x The corresponding sector includes both the tooth group 11 of the x-th phase conductor 3 and the tooth group 11 of other phase conductors 3.

[0142] This embodiment of the motor, while maintaining the same performance, reduces the number of tooth sets 11 in each stator core 1. This increases the spacing between adjacent tooth sets 11, reducing the machining difficulty of a single stator core 1. Furthermore, the number of winding phases in a single stator core 1 is correspondingly reduced, further decreasing the winding difficulty. When improved motor performance is required, the radial dimension of the motor can be increased, and performance parameters can be improved by expanding the axial dimension.

[0143] In some embodiments, the drive signal strength is consistent across all phases of the rotor 2's target speed range. The drive signal strength is characterized by its amplitude. Furthermore, the drive signal frequency is the same across all phases of the rotor 2's conductors 3.

[0144] The driving mode of this embodiment is mainly suitable for the case of a small number of motor phases. In order to meet the working index requirements, all phases are energized in any working condition, and the capacity of the motor can be fully utilized.

[0145] In some embodiments, in the case where the target torque of the rotor 2 is higher than the first preset torque, the driving signals input to the conductive wires 3 of the phases are of the same strength;

[0146] In the case where the target torque of the rotor 2 is not higher than the first preset torque, the driving signals input to the conductive wires 3 of some phases have a preset strength, and the driving signals input to the conductive wires 3 of the remaining phases are lower than the preset strength or are not driven.

[0147] For example, in the case of a large number of motor phases, such as 5 phases, a large torque is generally required at low speed, i.e., the target torque is higher than the first preset torque, and the driving signals can be input to the 5 conductive wires 3 at the same time. At high speed, only a small torque is generally required, i.e., the target torque is not higher than the first preset torque, and the 1st, 3rd and 5th phases among the 5 conductive wires 3 are energized and driven, and the 2nd and 4th phases are not driven or are driven with a weak current. The torque is related to the number of driving phases and the amplitude of the driving signal, and the speed is related to the frequency of the driving signal. Such a motor can be used as a power motor of a vehicle to achieve a specific driving mode by increasing the number of phases, thereby solving the technical problem of difficulty in selecting a power motor.

[0148] The driving mode of this embodiment is mainly suitable for the case of a wide range of load torques. By increasing the number of phases, some phases can be flexibly selected for driving according to the torque requirements in actual work, or all phases can be selected for driving, so that the motor can meet the performance requirements in different working conditions and reduce the difficulty in selecting the motor.

[0149] In this embodiment, the strengths (represented by amplitudes) of the driving signals input to the conductive wires 3 of the phases are allowed to be different, but the frequencies of the driving signals input to the conductive wires 3 of the phases are equal. By inputting driving signals of different strengths to the conductive wires 3 of the phases, in addition to the above-mentioned adaptability to different working conditions, efficiency maximization can also be achieved in control. Specifically, the motor has a load inertia during operation. At the appropriate time, reducing the driving current will reduce the driving torque, and the load inertia can make up for the output torque of the motor. Through this control mode, efficiency maximization and power consumption reduction can be achieved.

[0150] In some embodiments, as shown in Figure 6 the motor has a first working mode. In the first working mode, each phase conductive wire 3 is energized in the whole time period, and the driving signals between adjacent phase conductive wires 3 have a phase difference.

[0151] The motor adopts a cross energization driving mode. Each phase conductor 3 is connected to a continuous driving signal, and the driving signals between adjacent phase conductors 3 have a phase difference. The driving signal can be a sine wave, a square wave or other continuous waveforms. Different driving waveforms can be achieved by electronic commutators, such as silicon-controlled rectifiers, Mos or IGBT, etc. The commutation phase difference between the driving signals can be 1° to 180°. The advantage of using a sine wave to drive is that the driving noise is small, the linearity is good, and the efficiency is higher in the case of large torque or acceleration. The advantage of using a square wave to drive is that the position sensor structure is simple, the cost is low, and the position signal only needs to be logically processed, which can increase the output torque.

[0152] The winding of the motor in this embodiment is continuously energized, and the utilization rate of the winding and the stator core can reach 100%, thereby increasing the working efficiency of the motor. Moreover, the energization of each phase conductor 3 does not need to be frequently switched, which can reduce the working noise. In addition, stable and continuous energization during driving can make the law of the reaction force of the stator core 1 when the stator core 1 generates a magnetic pull consistent with the rotation direction, and the force is uniform in the steady-state driving, which is not easy to produce shaking in the stator core 1, and can improve the working stability and overall life of the motor.

[0153] In some embodiments, as shown in Figure 7 and Figure 8 , the motor has a second working mode. In the second working mode, each phase conductor 3 is intermittently energized, and the driving signals between adjacent phase conductors 3 have a phase difference.

[0154] The motor adopts an alternate energization driving mode. Each phase conductor 3 is connected to a non-continuous driving signal, and the driving signals between adjacent phase conductors 3 have a phase difference. Taking a two-phase motor as an example, as shown in Figure 7 , the driving signal is a non-continuous sine wave; and as shown in Figure 8 , the driving signal is a square wave.

[0155] Referring to Figure 7 , the driving signal of the first phase conductor can be obtained by advancing the commutation position of the continuous sine wave signal by a phase angle of f1’ and lagging by a phase angle of f1”, and the driving signal of the second phase conductor can be obtained by advancing the commutation position of the continuous sine wave signal by a phase angle of f2’ and lagging by a phase angle of f2”.

[0156] The driving signal provided to each phase conductor 3 is preferably commutated at the point where the tooth group 11 and the pole are in alignment. However, in practice, the commutation point cannot be accurately controlled to occur at the point where the tooth group 11 and the pole are in alignment due to various reasons (for example, the average distribution angle of the magnetic ring of the brushless motor is not accurate due to production; for example, the driving detection of the brushless motor is not accurate). The commutation point is advanced or delayed to some extent, which causes the winding to do useless work during the period of advance or delay, thereby reducing the efficiency of the brushless motor.

[0157] By providing a discontinuous driving signal, the useless work done by the winding can be reduced, thereby improving the efficiency of the brushless motor.

[0158] Referring to Figure 8 The control of the driving signal with a square wave is simpler. Therefore, in the alternating energization mode, the driving signal with a square wave is used to drive the brushless motor, which can further simplify the control.

[0159] The intermittent energization of the winding of the motor of the embodiment can increase the output torque of the motor, the control is simple, and the driving control cost can be reduced under specific design matching. Although the utilization rate of the stator core and the winding of such a motor is slightly reduced, it is already superior to the brush motor on the market, and the utilization rate of the stator core and the winding of most brush motors is only about 30%.

[0160] For the above-mentioned cross energization and alternating energization, the motor control program and the position of the Hall detection are different, the calculation and consideration of the internal winding of the motor are different, and the output power of the motor is different, so one motor generally uses one driving mode. For the needs of specific motors, without giving priority to cost, the driving mode of combining alternating energization and cross energization can be used, such as for power motors, alternating energization is used to improve the torque at low speed, and cross energization is used to improve the efficiency at high speed, so as to more fully meet the use requirements of the motor.

[0161] It should be understood that the above merely illustrates that the driving signal in the cross energization driving mode conforms to a sine function, and the waveform of the driving signal in the alternating energization driving mode is a square wave, and the embodiments of the disclosure are not limited thereto.

[0162] In some embodiments, one of the cross energization and the alternating energization driving modes can be used to drive the brushless motor. In other embodiments, the brushless motor can also be driven in the combined mode of cross energization and alternating energization.

[0163] According to the positional relationship between the stator core 1 and the rotor 2, the following embodiments of three different structures of motors are given.

[0164] In some embodiments, as shown in Figure 1 and Figure 2 The magnetic ring 21 is sleeved outside the stator core 1. The tooth 11' includes a neck 111 and a shoe 112 connected to form a T shape, the neck 111 is connected to the outer peripheral wall of the yoke 12, and the shoe 112 is arranged at the radially outer end of the neck 111, and the shoe 112 has a gap with the magnetic ring 21.

[0165] The outer rotor motor of this embodiment can achieve larger torque under the condition that the circumferential size is constant, because the force arm of the magnetic field force generated by the energization of the coil 31 is larger.

[0166] In some embodiments, as shown in Figure 4 and Figure 5 The stator core 1 is annular and sleeved outside the magnetic ring 21. The tooth 11' includes a neck 111 and a shoe 112 connected to form a T shape, the neck 111 is connected to the inner peripheral wall of the yoke 12, and the shoe 112 is arranged at the radially inner end of the neck 111, and the shoe 112 has a gap with the magnetic ring 21.

[0167] The inner rotor motor of this embodiment can achieve larger rotational speed under the condition that the circumferential size is constant, and the coil 31 is located outside the magnetic ring 21, so the heat dissipation is better, and the maintenance is convenient. For example, the inner rotor motor can be used in electric vehicles and other places where heat dissipation is required and assembly is convenient.

[0168] In some embodiments, as shown in Figures 15 to 19 , the stator core 1 and the magnetic ring 21 are arranged in an axial superposition manner, and the magnetic ring 21 at least partially covers the coil 31 in the radial direction of the stator core 1.

[0169] In which, Figure 15 is a structural schematic diagram of the stator core 1, the yoke 12 is in the form of a ring-shaped disc, a plurality of tooth groups 11 are arranged at the end of the yoke 12, for example, only a single tooth 11' is included in the tooth group 11, and the tooth 11' is generally in the form of a trapezoid. The four corners of the trapezoid can be provided with rounded corners, and the radial inner and outer sides can be provided in the form of a circular arc. The wire 3 is wound around the outer periphery of the tooth 11'.

[0170] Figure 16 is a structural schematic diagram of the magnetic ring, Figure 17 The structure of the stator core 1 and the magnetic ring 21 arranged in an axial superposition manner is shown, the magnetic ring 21 at least partially covers the coil 31 in the radial direction of the stator core 1, so the magnetic ring 21 needs to be arranged in a larger width, in order to enable the magnetic field force generated by the energization of the coil 31 to effectively act on the magnetic ring 21, the magnetic ring 21 fully covers the coil 31 in the radial direction of the stator core 1. The shaft 22 is connected to the central region of the magnetic ring 21, and the two ends of the shaft 22 exceed the stator core 1 and the magnetic ring 21.

[0171] The planar motor of the embodiment has a small size, a flat and thin overall shape, and can be used in a limited installation space, and can achieve large torque and large power.

[0172] In some embodiments, as shown in Figure 18 the stator core 1 is provided with a magnetic ring 21 on both sides in the axial direction; as shown in Figure 19 the magnetic ring 21 is provided with a stator core 1 on both sides in the axial direction; or, the motor includes a plurality of stator cores 1 and a plurality of magnetic rings 21, and the stator cores 1 and the magnetic rings 21 are alternately arranged in the axial direction, so as to satisfy that the stator core 1 is provided with a magnetic ring 21 on both sides in the axial direction, and the magnetic ring 21 is provided with a stator core 1 on both sides in the axial direction.

[0173] The motor of the embodiment can achieve greater torque, thereby improving the power density.

[0174] Secondly, the present disclosure provides a device including the motor of the above-mentioned embodiments. For example, the device can be related to the fields of electrical servo transmission, information processing, transportation, household appliances, consumer electronics, national defense, and special purposes.

[0175] Since the motor of the embodiment of the present disclosure has better comprehensive performance, for example, the torque and power can be increased, the working efficiency, stability and life can be improved, the working noise can be reduced, the number of magnetic poles can be reduced when the number of teeth is the same, thereby reducing the driving difficulty, improving the degree of automation and efficiency of winding, and the like, therefore, such motor can well meet the driving requirements of different devices in different fields, and is easier to select.

[0176] Finally, the present disclosure provides a manufacturing method based on the motor of the above-mentioned embodiments, as shown in Figure 2 In some embodiments, the manufacturing method includes:

[0177] The wire providing step: providing a wire 3;

[0178] The winding step: winding the wire 3 on the tooth groups 11 in different phase sequence orders until the coils 31 are formed on each tooth group 11; in the same phase corresponding to all the coils 31, the number of tooth groups 11 between the coils 31 on the adjacent two tooth groups 11 is X-1, and the winding direction of the coils 31 on the adjacent two tooth groups 11 is opposite along the circumferential direction of the tooth group 11;

[0179] The wire breaking step: breaking the wire 3 at the connection of adjacent phase sequences, so that the total number of phases of the wire 3 is X, and each phase of the wire 3 has an independent first end and a second end.

[0180] For example, Figure 2As shown in the two-phase motor, a wire 3 is wound from X1-IN, and then wound every other tooth group 11, and the winding direction of the adjacent tooth groups 11 is opposite along the circumferential direction of the tooth group 11. After the wire 3 is wound around the whole circumference and is led out from X1-OUT, the wire 3 is wound again from the position of X2-IN, and then wound every other tooth group 11 until it is led out from X2-OUT. Finally, the connection between X1-OUT and X2-IN is disconnected to form the X1 and X2 phase wires 3.

[0181] In this embodiment, one wire 3 is used to wind all the phases without interruption, which is conducive to the automation of winding. Moreover, the wires 3 of the same phase are alternately wound, the winding method is simple, and since the wires 3 of each phase are independent of each other, the wires 3 of each phase can have a first end and a second end after being wound automatically, which reduces the winding and eliminates the need for manual trimming, so that the next process can be entered, and the degree of automation of winding is improved, thereby improving the production efficiency and the success rate of winding.

[0182] Some specific embodiments of the motor of the present disclosure are given below.

[0183] In the first embodiment, as shown in Figure 1 and Figure 2 The motor includes a stator core 1, the stator core 1 includes a yoke 12 and a plurality of tooth groups 11, the plurality of tooth groups 11 are uniformly spaced along the circumferential direction of the stator core 1 and connected to the outer circumference of the yoke 12, the yoke 12 is a circular ring, and each tooth group 11 includes a single tooth 11'. The tooth 11' includes a neck portion 111 and a shoe portion 112, the shoe portion 112 is connected to the radially outer end of the neck portion 111 to form a T-shaped structure.

[0184] The magnetic ring 21 is coaxially sleeved outside the stator core 1. Since the force arm of the magnetic field force generated by the coil 31 is larger, a larger torque can be achieved under the condition that the circumferential dimension is constant.

[0185] The two-phase wire 3 is wound on the tooth 11' to form a coil 31, and each phase wire 3 has an independent first end and a second end, for example, the X1 phase wire 3 has X1-IN and X1-OUT, and the X2 phase wire 3 has X2-IN and X2-OUT. For the same phase wire 3, the number of teeth 11' spaced between the adjacent two coils 31 is 1, and the winding direction of the adjacent two coils 31 is opposite along the circumferential direction of the tooth 11', and the adjacent two coils 31 are connected by a connecting segment 32. X2-IN, X1-IN, X2-OUT and X1-OUT are led out from the adjacent four teeth 11' along the circumferential direction.

[0186] For example, in the case of selecting the pole number P of the magnetic ring 21 to be 4 and the total number of phases X of the wire 3 to be 2, the remaining structure and the driving parameter design are as follows:

[0187] The number of teeth 11' is Z = P * X = 4 * 2 = 8;

[0188] The single-pole included angle β of the magnetic ring 21 is 360° / P = 360° / 4 = 90°;

[0189] The central angle of the circular arc between the center positions of the two gaps on the two sides of the tooth 11' where the X1 and X2 phases are located in the circumferential direction of the stator core 1 is β1 = β2 = 45°;

[0190] The phase difference θ of the two-phase driving signals 12 = 2 * 45° = 90°.

[0191] Based on the above structure, when winding, the X1 phase wire 3 corresponds to the teeth 11' numbered 1, 3, 5, and 7, and is alternately and reversely wound along the circumferential direction of the tooth 11', forming two outgoing lines X1-IN and X1-OUT; the X2 phase wire 3 corresponds to the teeth 11' numbered 2, 4, 6, and 8, and is alternately and reversely wound along the circumferential direction of the tooth 11', forming two outgoing lines X2-IN and X2-OUT. The four outgoing lines correspond to four connection ports of the two-phase driving on the driving board.

[0192] As shown in Figure 6 , the driving signals of the two-phase motor are continuous sine waves, for example, the amplitudes and frequencies of the two-phase sine waves can be the same, and the phase difference is 90°, which can be accurately controlled by software. In addition, the data for driving the motor are calculated in advance by software, and the waveform of the driving is output according to the demand for the speed of the motor, so as to accurately control the independent power supply of each channel.

[0193] Each phase wire 3 is powered at all times, the driving mode is cross power supply, and the two independent waveforms with a phase difference of 90° are switched once, so as to realize the rotation of a pair of NS pole rotors, the driving is simple, the switching is stable, the working efficiency of the motor can be increased, the working stability and overall life of the motor can be improved, and the working noise can be reduced. For different loads within the rated working range, no debugging is needed and it can be directly used. In the driving signal of each phase in a cycle, the direction of the driving signal needs to be switched four times.

[0194] As shown in Figure 7 , the driving signals of the two-phase motor are discontinuous sine waves.

[0195] As shown in Figure 8 , the driving signals of the two-phase motor are intermittent square waves, and the driving mode is alternate power supply, which can increase the output torque of the motor, simplify the control difficulty, and reduce the cost.

[0196] The motor of the present disclosure is driven by alternating current, and the following three schemes can be used to realize two groups of alternating current input:

[0197] 1, in the AC output with the principle of capacitive phase shift, single-phase AC into two-phase AC phase difference 90 °, the motor can be directly driven, the frequency of AC is 50 Hz, so the speed of the motor is constant, to control the speed of the motor must change the frequency of AC, this way is difficult to speed up;

[0198] 2, AC through AC-DC switching power supply inverter into a predetermined voltage DC, then through the MOS tube control inverter into a predetermined voltage AC, and then into two phase difference 90 ° AC power supply for motor, can realize the drive, this scheme is relatively simple speed regulation;

[0199] 3, AC through rectifier bridge into 310 V DC, then through the MOS tube control inverter into a specified voltage AC, and then into two phase difference 90 ° AC power supply for motor, can realize the drive, this scheme is also simple speed regulation.

[0200] In the second embodiment, as shown in Figure 4 and Figure 5 The difference between the first embodiment is that the neck 111 is connected to the inner wall of the yoke 12, and the shoe 112 is provided at the radially inner end of the neck 111. This kind of inner rotor motor can achieve a larger speed under the condition of a certain circumferential size, and because the coil 31 is located outside the magnetic ring 21, the heat dissipation is better, and the maintenance is convenient. The winding method and driving method of the second embodiment can refer to the first embodiment.

[0201] In the third embodiment, as shown in Figure 9 and Figure 10 The difference between the first embodiment is that the three-phase wire 3 is wound on the tooth 11' to form a coil 31 on the tooth 11', and each phase wire 3 has an independent first end and a second end, for example, the X1 phase wire 3 has X1-IN and X1-OUT, the X2 phase wire 3 has X2-IN and X2-OUT, and the X3 phase wire 3 has X3-IN and X3-OUT. For the same phase wire 3, the number of teeth 11' between the adjacent two coils 31 is 2, and the winding direction of the adjacent two coils 31 along the tooth 11' is opposite, and the adjacent two coils 31 are connected through the connecting segment 32. X3-IN, X2-IN, X1-IN, X3-OUT, X2-OUT and X1-OUT are led out from the adjacent six tooth groups 11 along the circumferential direction.

[0202] For example, in the case of selecting the pole number P of the magnetic ring 21 = 4 and the total phase number X of the wire 3 = 3, the remaining structure and driving parameter design are as follows:

[0203] The number of teeth 11' Z = P * X = 4 * 3 = 12;

[0204] The single-pole included angle β of the magnetic ring 21 is 360° / P = 360° / 4 = 90°.

[0205] The central angle of the circular arc between the gaps on both sides of the tooth 11' where X1, X2 or X3 phase is located and the center position in the circumferential direction of the stator core 1 is β1 = β2 = β3 = 30°.

[0206] As shown in the figure, in the three-phase drive signal, the phase difference θ Figure 11 between X1 and X2 phases is 2x30° = 60°; the phase difference θ between X2 and X3 phases is 2x30° = 60°; and the phase difference θ

[0207] between X1 and X3 phases is 2x60° = 120°. 12 23 13

[0208] As shown in the figure, the drive signal of the two-phase motor is an intermittent square wave, the amplitude and frequency of the three-phase square wave can be the same, and the calculation method of the phase difference between the three-phase drive signals is the same as Figure 12 , the phase difference between the drive signals of the adjacent two phases is 60°. The three-phase conductors 3 are intermittently energized, and the driving mode is alternate energization. Figure 11

[0209] Compared with the two-phase motor, the three-phase motor can realize greater driving torque. In operation, all three-phase conductors 3 can be energized, or some of the three-phase conductors 3 can be energized according to the actual torque requirement.

[0210] In the fourth embodiment, as shown in Figure 13 and Figure 14 , the difference from the first embodiment is that the space occupied by the tooth 11' corresponding to the different phase conductors 3 in the circumferential direction of the stator core 1 is different, that is, the teeth 11' corresponding to the different phase conductors 3 are not uniformly distributed in the circumferential direction of the stator core 1, but the teeth 11' corresponding to the same phase conductor 3 are uniformly distributed in the circumferential direction of the stator core 1. For example, the circumferential length of the shoe portion 112 of the tooth 11' corresponding to the X1 phase conductor 3 is smaller than the circumferential length of the shoe portion 112 of the tooth 11' corresponding to the X2 phase conductor 3.

[0211] The number of teeth 11' Z = P*X = 4x2 = 8;

[0212] The single-pole included angle β of the magnetic ring 21 is 360° / P = 360° / 4 = 90°.

[0213] ​​​The central angles corresponding to the arcs between the gaps on both sides of tooth 11' where phases X1 and X2 are located and the center position of the stator core 1 circumferentially upward are β1 = 22.5° and β2 = 67.5°.

[0214] Phase difference θ of the two-phase drive signals 12 =2 x 22.5° = 45°.

[0215] like Figure 14 As shown, the drive signal for the two-phase motor is a continuous sine wave. For example, the amplitude and frequency of the two-phase sine waves can be the same, and the phase difference is 45°. Each phase conductor is energized at all times, and the drive method is cross-energization, which can increase the motor's working efficiency, improve the motor's working stability and overall lifespan, and reduce operating noise. In one cycle of the drive signal for each phase, the direction of the drive signal needs to be switched four times.

[0216] In the fifth embodiment, as Figures 15 to 19 As shown, the difference from the first embodiment is that the yoke 12 has an annular disc structure, and multiple tooth sets 11 are provided at the ends of the yoke 12. For example, the tooth set 11 includes only a single tooth 11', and each tooth 11' is generally trapezoidal in shape. The four corners of the trapezoid can be rounded, and the radial inner and outer sides can be rounded. The wire 3 is wound around the outer periphery of the tooth 11'.

[0217] Figure 16 This is a schematic diagram of the magnetic ring structure. Figure 17 The diagram illustrates a structure in which the stator core 1 and magnetic ring 21 are stacked axially. The magnetic ring 21 at least partially covers the coil 31 radially along the stator core 1. To ensure that the magnetic force generated by the energized coil 31 effectively acts on the magnetic ring 21, the magnetic ring 21 completely covers the coil 31 radially along the stator core 1. The outer diameters of the stator core 1 and the magnetic ring 21 can be the same. This type of planar motor is small in size, with a flat and thin overall shape, making it suitable for applications with limited installation space. It also enables high torque and high power output.

[0218] like Figure 18 As shown, magnetic rings 21 are provided on both sides of the stator core 1 along the axial direction; as Figure 19 As shown, the magnetic ring 21 has stator cores 1 on both sides along the axial direction; or, the motor includes multiple stator cores 1 and multiple magnetic rings 21, with the stator cores 1 and magnetic rings 21 arranged alternately along the axial direction.

[0219] For each of the above embodiments, in addition to the advantages given above, such a motor uses no need to make the motor, drive circuit board, drive program and load to correspond to debugging development, select a motor speed and power, and can select the corresponding drive control board to achieve maximum efficiency drive. Because the drive signal of such a motor and the speed and magnetic ring are all corresponding, that is, through the Hall sensor and the program in the chip to judge the accurate commutation, the same motor matching different loads no longer needs to accurately debug the time point of commutation, the built-in program can increase the simple logic to realize the early judgment, and ensure the maximum efficiency of the motor. For example, a motor with an output power of 20W and a speed of 1500rpm can drive various fan loads of about 5W to 15W without secondary debugging, and can all approach or reach the maximum 99% efficiency point.

[0220] However, the six switching processes of the traditional three-phase motor are realized by complex Foc (field oriented control) algorithm, and if no secondary debugging is made for the corresponding load, the efficiency of the motor will be greatly reduced. For example, a traditional three-phase motor with an output power of 20W and a speed of 1500rpm, when driving various fan loads of about 5W to 15W, if no secondary debugging is made, the efficiency of the motor may be lower than 90% when working at 15W, and even may be lower than 80%. If secondary debugging is made, the highest efficiency can reach more than 95%, and the maximum efficiency point of the motor debugged by different personnel will also be different.

[0221] Although some specific embodiments of the present disclosure have been described in detail through examples, those skilled in the art should understand that the above examples are only for illustration, and are not intended to limit the scope of the present disclosure. Those skilled in the art should understand that the above embodiments can be modified or some technical features can be replaced equivalently without departing from the scope and spirit of the present disclosure. The scope of the present disclosure is defined by the appended claims.

Claims

1. A brushless electric motor characterized by, Comprise: At least one stator core (1) comprising a plurality of tooth groups (11) arranged at intervals along the circumference thereof, the total number of the tooth groups (11) being Z; A rotor (2) rotatable relative to the stator core (1), the rotor (2) comprising a plurality of magnetic rings (21) with a pole number P, P being an even number; and At least two phase conductors (3) wound on the tooth groups (11) to form coils (31) on the tooth groups (11), the total number of phases of the conductors (3) being X, each phase of the conductors (3) having independent first and second ends; for the same phase of the conductors (3), the number of tooth groups (11) spaced between the coils (31) on the adjacent two tooth groups (11) is X-1, and the winding directions of the coils (31) on the adjacent two tooth groups (11) along the circumference of the tooth groups (11) are opposite; Wherein, Z=P*X; Wherein, the at least two phase conductors (3) are sequentially wound along the circumference of the stator core (1) from the first phase to the Xth phase. The conductors (3) to which the drive signals are applied include an i-th phase conductor (3) and a k-th phase conductor (3), and the phase difference θ between the drive signal of the i-th phase conductor (3) and the drive signal of the k-th phase conductor (3) ik = , where 1≤i In the same stator core (1), the tooth group (11) of the xth phase conductor (3) and the two adjacent tooth groups (11) have gaps at the closest positions, and the gaps have central positions in the circumferential direction of the stator core (1); in all the gaps formed by the Z tooth groups (11), the central angle of the circle center corresponding to the circular arc between the central position of the xth phase conductor (3) and the adjacent central position in the circumferential direction of the stator core (1) is , and The corresponding sector includes at least part of the tooth group (11) of the xth phase conductor (3).

2. The brushless motor according to claim 1, characterized in that: The tooth groups (11) comprise a single tooth (11'), and the conductors (3) are wound on the tooth (11') to form coils (31) on the tooth (11'); and / or The tooth groups (11) comprise at least two teeth (11'), which are arranged at intervals along the circumference of the stator core (1), and the conductors (3) are wound on the at least two teeth (11') to form coils (31) on the at least two teeth (11').

3. The brushless motor of claim 1, wherein, Each phase of the conductors (3) is configured to pass through an independent driving signal.

4. The brushless motor of claim 1, wherein, In the radial direction of the stator core (1), the winding directions of each coil (31) formed by the at least two phase conductors (3) are consistent.

5. The brushless motor of claim 4, wherein, The starting winding positions of each coil (31) formed by the at least two phase conductors (3) are located on the side away from the rotor (2).

6. The brushless motor of claim 1, wherein, In the radial direction of the stator core (1), the first and second ends of the at least two phase conductors (3) are led out from the same side of the tooth groups (11).

7. The brushless motor of claim 1, wherein, In the circumferential direction of the stator core (1), all the first and second ends are led out from a plurality of adjacent tooth groups (11).

8. The brushless motor of claim 7, wherein, Wherein, The winding directions of the same number of coils (31) from the first end of the at least two phase conductors (3) along the circumference of the tooth groups (11) are consistent; or The winding directions of the same number of coils (31) from the first end of at least one group of adjacent two phase conductors (3) along the circumference of the tooth groups (11) are opposite.

9. A brushless motor according to any one of claims 1 to 8, characterized in that A plurality of the stator cores (1) are arranged in the axial direction, and each of the stator cores (1) comprises at least one phase of the conductors (3), and the tooth groups (11) of the plurality of stator cores (1) are arranged staggered in the circumferential direction of the stator core (1).

10. A brushless motor according to any one of claims 1 to 8, characterized in that In the entire target speed range of the rotor (2), the driving signal strengths passed through by the conductors (3) of all phases are consistent.

11. The brushless motor according to any one of claims 1-8, characterized in that, In the case that the target torque of the rotor (2) is higher than a first preset torque, the driving signals input to the conductors (3) of each phase are of the same strength; In the case that the target torque of the rotor (2) is not higher than the first preset torque, the driving signals input to the conductors (3) of some phases have a preset strength, and the driving signals input to the conductors (3) of the remaining phases are lower than the preset strength or are not driven.

12. The brushless electric motor according to any one of claims 1 to 8, characterized in that The brushless motor has a first working mode, in which the conductors (3) of each phase are energized in a full period, and the driving signals between the conductors (3) of adjacent phases have a phase difference.

13. The brushless electric motor according to any one of claims 1 to 8, characterized in that The brushless motor has a second working mode, in which the conductors (3) of each phase are intermittently energized, and the driving signals between the conductors (3) of adjacent phases have a phase difference.

14. The brushless motor according to any one of claims 1-8, characterized in that: The magnetic ring (21) is sleeved outside the stator core (1).

15. A brushless motor according to any one of claims 1 to 8, wherein The stator core (1) is annular and is sleeved outside the magnetic ring (21).

16. The brushless electric motor according to any one of claims 1 to 8, characterized in that The stator core (1) and the magnetic ring (21) are arranged in an axial stack, and the magnetic ring (21) at least partially covers the coils (31) in the radial direction of the stator core (1).

17. The brushless motor according to claim 16, characterized in that: The stator core (1) is provided with the magnetic ring (21) on both sides in the axial direction; and / or The magnetic ring (21) is provided with the stator core (1) on both sides in the axial direction.

18. A manufacturing method of the brushless motor according to any one of claims 1 to 17, characterized by, Comprising: A wire supply step of providing a conductor (3); A winding step of winding the conductor (3) on the tooth groups (11) in different phase sequence orders until the coils (31) are formed on each tooth group (11); in the same phase corresponding to all the coils (31), the number of tooth groups (11) between the coils (31) on the adjacent two tooth groups (11) is X-1, and the winding directions of the coils (31) on the adjacent two tooth groups (11) are opposite in the circumferential direction of the tooth groups (11); A wire breaking step of breaking the conductor (3) at the connection of adjacent phase sequences, so that the total number of phases of the conductor (3) is X, and each phase conductor (3) has an independent first end and a second end.

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