Axial flux motor, gear motor and conveyor

Abstract

An axial flux motor comprises a housing (1) having a base plate (10), a PCB (2), a stator (3) and a rotor (4), where the PCB (2) is arranged between the base plate (10) and the stator (3), and where the rotor (4) is arranged in a receptacle (12) of the housing (1), which receptacle (12) has a sleeve shape and extends from the base plate (10) coaxially with the stator (3), where a slot (120) is formed in the receptacle (12), which slot (120) extends from the base plate (10) to a free end of the receptacle (12), wherein the PCB (2) comprises an island (21), and wherein a reference magnet (43) facing the PCB (2) is arranged on a first free end of the shaft (40), and wherein a sensor (23) facing the shaft (40) is arranged on the island (21) of the PCB (2), and the reference magnet (43) and the sensor (23) together form a position sensor for the rotor (4).

Description

Technical Field

[0001] The present invention relates to electric motors, and in particular to axial flux electric motors. Background Art

[0002] Known embodiments of such axial flux motors include a housing in which a stator with coils is concentrically arranged around a rotor shaft, which is rotatably mounted in the housing. A magnetic disk is attached to the shaft, adjacent to the stator and covering the stator coils. A printed circuit board (PCB) is positioned adjacent to the stator, opposite the magnetic disk. The PCB is in the form of an annular disk from which the shaft protrudes. With this design, integrating shaft position detection is complex to manufacture or assemble. For example, it requires complex housing fabrication or complex wiring. Summary of the Invention

[0003] The object of the present invention is to provide an axial flux machine with shaft position detection which avoids the above-mentioned disadvantages.

[0004] This object is achieved by an axial flux motor having the features of claim 1. Further embodiments of the axial flux motor, of a geared motor having such an axial flux motor, and of a conveyor having such an axial flux motor are defined by the features of the further claims.

[0005] The axial flux motor according to the present invention includes: a housing having a base plate; a printed circuit board (PCB); a stator having a coil and an iron core; and a rotor having a shaft, a disk, and a drive magnet. The PCB is arranged between the base plate and the stator, and the rotor is arranged in a receiver of the housing, the receiver having a sleeve shape and extending coaxially from the base plate to the stator between the coils. A slot is formed in the receiver, the slot extending from the base plate to the free end of the receiver. The PCB includes a recess from which the receiver protrudes; an island arranged in a central portion of the receiver; and a connecting bridge connecting the island with the rest of the PCB and arranged in the slot of the receiver. A reference magnet facing the PCB is arranged on the first free end of the shaft, and a sensor facing the shaft is arranged on the island of the PCB, and the reference magnet and the sensor together form a position sensor for the shaft.

[0006] The advantage of this design is that the sensor is integrated into the PCB and no additional wiring is required, allowing easy assembly of the axial flux motor.

[0007] The stator core can be a sintered core. The receiver can be formed as a single piece integrally with the base plate of the housing. Alternatively, the receiver can be a separate piece fixed to the base plate. The space between the sidewalls and the receiver can be filled with resin, completely surrounding the PCB in this area and at least laterally surrounding the stator. The resin can contain epoxy, etc. The top portion of the core and coils is free of resin.

[0008] In one embodiment, the shaft is positioned in a receiver along with at least one bearing. The bearing closest to the baseplate rests on a shoulder of the receiver. Depending on the size of the motor, two or more bearings may be positioned in the receiver. The bearings may be any type of rolling element bearing or plain bearing.

[0009] In one embodiment, the shaft comprises a collar which rests with its side facing the base plate on a bearing furthest away from the base plate, and the disc rests on the collar on its side facing away from the base plate.

[0010] In one embodiment, a first bolt is provided on the side of the second free end of the shaft opposite the first free end, the first bolt being arranged in a complementary recess of the disk so as to form a form-fitting and / or force-fitting connection.

[0011] In one embodiment, the axial flux electric machine includes a shaft extension that is disposed in a socket formed in the first bolt that is complementary to the shaft extension.

[0012] In one embodiment, a second bolt is provided at the second free end of the shaft.

[0013] In one embodiment, the reference magnet is arranged in a recess in the front surface of the shaft.

[0014] In one embodiment, a third bolt is provided on the side of the disk facing away from the base plate.

[0015] In one embodiment, cooling ribs are provided on the side of the base plate opposite to the PCB.

[0016] In one embodiment, the lateral sidewalls extend away from the base plate in the direction of the disk or in the direction of the PCB. The sidewalls may extend beyond the coils and core of the stator. They may also extend beyond the disk and / or beyond the shaft. The sidewalls may be formed integrally with the base plate as a single piece.

[0017] In one embodiment, a cutout is formed in one of the side walls of the housing, and wherein the PCB includes a connector that is externally accessible through the cutout.

[0018] For example, the housing may be made of aluminum, the stator core may be made of sintered metal, the coils may be made of copper, the rotor disks may be made of sintered steel, and the rotor shaft may be made of stainless steel.

[0019] The features of the above-described embodiments of the axial flux machine may be used in any combination unless they contradict each other.

[0020] The reduction motor according to the present invention comprises a gearbox having a driving gear and at least one driven gear, and the axial flux motor according to any one of the aforementioned embodiments, wherein the driving gear is fixed to the shaft.

[0021] The conveyor according to the invention comprises a conveying device operatively connected to an axial flux motor according to any of the preceding embodiments or to the above-described reduction motor.

[0022] In one embodiment, the conveyor comprises a power supply and / or control unit that supplies power and / or control signals to the axial flux motor or the reduction motor. Obviously, the power supply and / or control unit can receive signals from the axial flux motor, whether these signals are control signals, measurement signals or other signals. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The following describes an embodiment of the present invention in more detail with reference to the accompanying drawings. These are for illustrative purposes only and should not be construed as limiting. It shows:

[0024] Figure 1 is a perspective view of a first embodiment of an axial flux motor according to the present invention;

[0025] Figure 2 It passes through Figure 1 A cross-sectional view of the rotation axis of the axial flux motor;

[0026] Figure 3 yes Figure 1 A perspective view of a housing of an axial flux motor;

[0027] Figure 4 yes Figure 1 A three-dimensional diagram of the PCB of the axial flux motor;

[0028] Figure 5 is a cross-sectional view through the rotation axis of a second embodiment of an axial flux electric machine according to the present invention;

[0029] Figure 6 is a perspective view of a reduction motor according to the present invention;

[0030] Figure 7 It passes through Figure 6 A sectional view of the rotation axis of the reduction motor; and

[0031] Figure 8 is a perspective view of a conveyor according to the present invention. DETAILED DESCRIPTION

[0032] Figure 1A perspective view of a first embodiment of an axial flux motor according to the present invention is shown. The motor comprises a housing 1 having a base plate 10 and lateral side walls 11 extending from the lateral edges of the base plate 10. The base plate 10 has a substantially square layout. Reinforcement or fixing elements are arranged in the corners of the housing 1. In the depicted housing, these elements are formed integrally with the side walls and base plate as a single piece. A stator 3 with coils 30 is completely disposed within the housing. The coils are arranged evenly distributed around the axis of rotation R. A rotor 4 having a disk 41 is arranged above the stator 3, with the disk 41 completely covering all coils 30. The rotor 4 is arranged concentrically with the axis of rotation R and is rotatable about it. A third bolt 410 is arranged in the center of the disk 41, extending upward from the disk to provide a good connection to the driven element.

[0033] Figure 2 Shown through Figure 1A cross-sectional view of the rotation axis R of an axial flux motor. Sidewalls 11 and base plate 10 are integrally formed as a single piece. A receiver 12 extends upward from base plate 10 between sidewalls 11. Receiver 12 is integrally formed as a single piece with the base plate. On one side, receiver 12 includes a slot 120 that extends from the base plate across its entire height. Through slot 120, the PCB extends from an area outside the receiver into its interior. The receiver includes a shoulder 121 on which bearing 5 rests. The bearing shown is a double-row ball bearing. Shaft 40 is rotatably mounted in housing 1 by means of bearing 5. Shaft 40 includes a collar 44, one side of which rests on the bearing. A disk 41 rests on the other side of the collar. A reference magnet 43 is arranged at the lower free end of the shaft. In the depicted embodiment, the reference magnet is fixed in a recessed portion in the end face of shaft 40. The shaft extends beyond the bearing, leaving a small gap between the reference magnet and PCB 2, which integrates sensor 23. Reference magnet 43, together with sensor 23, forms a position sensor or an orientation detector for shaft 40 or rotor 4. A first bolt 400 is arranged at the upper free end of the shaft and is positioned in a complementary recess in disk 41. The disk has a sleeve that includes the recess and extends between the coils 30 of stator 3. A third bolt 410 is arranged on the other side of the sleeve, coaxial with the sleeve and the axis of rotation R. The core 31 of stator 3 is arranged on PCB 2 and extends upward toward the top opening of housing 1. The stator core and coils are completely covered by disk 41. The disk extends to the exterior of the housing in the direction of the axis of rotation R, that is, above the free upper edge of sidewall 1. Drive magnets 42 are arranged on the side of the disk facing PCB 2, evenly distributed around the circumference of the disk. Cooling ribs 13 are arranged on the outside of the housing 1 at the bottom plate 10 to provide good cooling for the PCB 2 and the entire stator. The PCB 2 is arranged inside the housing 1 and on the bottom plate 10. The short distance between the PCB and the cooling ribs 13 and the large contact area between the PCB and the bottom plate increase the cooling capacity.

[0034] Figure 3 Shown Figure 1 and Figure 2 A perspective view of the housing 1 of an axial flux motor. The receiver 12 comprises external reinforcing ribs 122 on the outside of the receiver, which extend from the base plate 10 over the entire height of the receiver and are distributed around the circumference of the receiver, and the receiver 12 comprises internal reinforcing ribs 123 on the inside of the receiver, which extend from the base plate 10 almost to the shoulder 121 and are oriented concentrically with the external reinforcing ribs 122.

[0035] Figure 4 Shown Figure 1 and Figure 2A perspective view of the PCB 2 of an axial flux motor. It is disc-shaped, with a substantially circular outer edge. A C-shaped recess 20 is formed in the PCB, concentric with the outer edge, creating an island 21 at the center of the PCB and a connecting bridge 22 connecting the outer ring of the PCB to the island. A sensor 23 is arranged in the center of island 21. An external gap 25 is arranged on the outside of recess 20, and an internal gap 26 is arranged on the inside of recess 20, where they complement the external and internal reinforcement ribs of the housing's receiver, respectively. The outer edge of the PCB includes straight sections 24 on two opposing sides, which, in the assembled state, are parallel to the corresponding side walls of the housing. Solder pads 27 are arranged in the edge region of the PCB, evenly distributed around its circumference. In the assembled state, the coils are soldered to these solder pads 27.

[0036] Figure 5 This is a cross-sectional view through the axis of rotation of a second embodiment of an axial flux motor according to the present invention. In this embodiment, the coils 30 and core 31 of the rotor 3 do not extend upward to the upper edge of the side wall 11, and the rotor disk 41 does not extend beyond the upper edge of the side wall. A first shaft bolt 400 extends through a complementary through-hole in the disk 41. A socket 401 is formed in the center of the first bolt for receiving a shaft extension 6. The shaft extension can be connected to the element to be driven.

[0037] Figure 6 A perspective view of a reduction motor according to the invention is shown. In this embodiment, the base plate 10 is substantially square and has rounded corners. The gearbox 7 is arranged on the free edge of the side wall 11 of the housing 1 of the axial flux motor.

[0038] Figure 7 Shown through Figure 6 sectional view of the reduction motor with the rotation axis R. In this embodiment, the shaft 40 includes a second bolt 402 arranged concentrically on the first bolt 400. The driving gear 70 of the gearbox 7 is fixed to the second bolt 402. The gearbox 7 includes a driven gear 71 that is operatively connected to the driving gear 70 directly or via some other gears. The rotation axis of the motor is coaxial with the axis of the driving gear and parallel to the driven gear axis G. A cutout 14 is formed in one side wall 11 of the housing 1, allowing access to the connector 28 arranged on the PCB 2 from the outside of the housing 1.

[0039] Figure 8 : is a perspective view of a conveyor according to the present invention. The conveyor includes Figure 6 and Figure 7A reduction motor is arranged in a molded part 90, and a roller 91 is rotatably mounted on the molded part 90 and operatively connected to the driven gear of the reduction motor. In the depicted embodiment, the roller comprises a transverse pulley connected to the reduction motor via a timing belt. A control unit 8 is arranged adjacent to the reduction motor and is connected to the axial flux motor connector 28 of the reduction motor via a cable and plug. The bottom plate and ribs of the axial flux motor housing are in contact with the molded part 90, thereby transferring heat from the motor to the molded part and from the molded part to its surroundings.

[0040] Reference Signs List

[0041] 1 housing 4 rotors

[0042] 10 base plates 40 shafts

[0043] 11 Side wall 400 first bolt

[0044] 12 receiver 401 socket

[0045] 120 groove 402 second bolt

[0046] 121 shoulder 41 plate

[0047] 122 external reinforcement rib 410 third bolt

[0048] 123 internal reinforcement rib 42 driving magnet

[0049] 13 cooling ribs 43 reference magnets

[0050] 14-cut 44-shaft collar

[0051] 2PCB 5 bearings

[0052] 20 recessed portion 6 axis extension portion

[0053] 21 island 7 gearbox

[0054] 22 connecting bridge 70 driving gear

[0055] 23 sensor 71 driven gear

[0056] 24 straight sections 8 control units

[0057] 25 External Clearance 9 Conveyor

[0058] 26 internal clearance 90 molded parts

[0059] 27 pads 91 rollers

[0060] 28 connectors

[0061] 3 Stator R rotation axis

[0062] 30 Coil G driven gear axis

[0063] 31 iron core

Claims

1. An axial flux motor, comprising: A housing (1) having a base plate (10); a PCB (2); a stator (3) having a coil (30) and an iron core (31); and a rotor (4) having a shaft (40), a disk (41) and a drive magnet (42), wherein the PCB (2) is arranged between the base plate (10) and the stator (3), and wherein the rotor (4) is arranged in a receiver (12) of the housing (1), the receiver (12) having a sleeve shape and extending from the base plate (10) between the coils (30) coaxially with the stator (3), It is characterized by: A slot (120) is formed in the receiver (12), the slot (120) extending from the base plate (10) to the free end of the receiver (12), The PCB (2) comprises: a recess (20) from which the receiver (12) protrudes; an island (21) arranged in a central portion of the receiver (12); and a connecting bridge (22) connecting the island (21) with the rest of the PCB (2) and arranged in the groove (120) of the receiver, and A reference magnet (43) is arranged on the first free end of the shaft (40) facing the PCB (2), and a sensor (23) is arranged on the island (21) of the PCB (2) facing the shaft (40), and the reference magnet (43) and the sensor (23) together form a position sensor for the rotor (4).

2. The axial flux motor according to claim 1, wherein: The shaft (40) is arranged in the receiver (12) together with at least one bearing (5), and wherein the bearing (5) closest to the base plate (10) rests on a shoulder (121) of the receiver (12).

3. The axial flux motor according to claim 1 or 2, wherein: The shaft (40) comprises a collar (44) which rests with its side facing the base plate (10) on the bearing (5) furthest away from the base plate (10), and the disc (41) rests on the collar (44) on its side facing away from the base plate (10).

4. An axial flux electric machine according to any one of the preceding claims, wherein A first bolt (400) is provided on the side of the second free end of the shaft (40) opposite the first free end, and the first bolt (400) is arranged in a complementary recess of the disk (41) to form a positive and / or force-fit connection.

5. The axial flux motor according to claim 4, comprising a shaft extension (6), the shaft extension (6) being arranged in a socket (401) formed in the first bolt (400) and complementary to the shaft extension (6).

6. The axial flux motor according to claim 4, wherein: A second bolt (402) is provided at the second free end of the shaft (40).

7. An axial flux electric machine according to any one of the preceding claims, wherein The reference magnet (43) is arranged in a recess in the front surface of the shaft (40).

8. An axial flux electric machine according to any one of the preceding claims, wherein A third bolt (410) is provided on the side of the disk (41) facing away from the base plate (10).

9. An axial flux electric machine according to any one of the preceding claims, wherein Cooling ribs (13) are provided on the side of the bottom plate (10) opposite to the PCB (2).

10. An axial flux electric machine according to any one of the preceding claims, wherein Transverse side walls (11) extend away from the base plate (10) in the direction of the tray (10).

11. The axial flux motor according to claim 10, wherein: A cutout (14) is formed in one of the side walls (11) of the housing (1), and wherein the PCB (2) includes a connector (28) accessible from the outside through the cutout (14).

12. A reduction motor comprising a gearbox (7) and an axial flux motor according to any one of the preceding claims, wherein the gearbox (7) has a driving gear (70) and at least one driven gear (71), wherein: The driving gear (70) is fixed to the shaft (40).

13. A conveyor (9) comprising a conveying device (91) operatively connected to an axial flux motor according to any one of claims 1 to 11 or a reduction motor according to claim 12.

14. The conveyor (9) according to claim 11, comprising a power and control unit (8) which supplies power and control signals to the axial flux motor according to any one of claims 1 to 11 or the reduction motor according to claim 12.

15. The conveyor (9) according to claim 14, wherein The power and control unit (8) receives control signals from the sensor (23).

Images