A small size transverse flux motor

Abstract

This invention relates to the field of transverse flux motor technology, and more particularly to a miniature transverse flux motor, comprising a motor housing and an electromagnetic core assembly. The electromagnetic core assembly includes a first stator core, a second stator core, and a magnetic ring disposed between the first and second stator cores. Both the first and second stator cores include several horseshoe-shaped stator blocks arranged in a circular pattern, and each stator core contains a coil winding. The magnetic ring includes a rotor body, a shaft, and permanent magnets. The shaft is coaxially fixed to the center of the rotor body, and the permanent magnets are evenly distributed at equal angles along the circumference of the rotor body. This invention employs a transverse flux structure with upper and lower double stators and a central magnetic ring. During operation, this is equivalent to two motors working collaboratively, significantly increasing the motor's output torque within the constraints of a miniature structure, effectively solving the problem of insufficient torque in existing miniature stepper motors and coreless motors.

Description

Technical Field

[0001] This invention relates to the field of transverse flux motor technology, and more particularly to a miniature transverse flux motor. Background Technology

[0002] Miniature motors are widely used in fields with strict space constraints, such as precision instruments, smart homes, medical equipment, and micro robots. Existing miniature motors are mainly stepper motors or coreless motors, but they generally have the technical defect of insufficient output torque, making it difficult to meet the needs of some scenarios for high torque and high torque density.

[0003] Axial flux is a common structure in existing stepper motors or coreless motors. However, its stator core is an integrated structure with tooth and yoke, and its multiple windings are mounted on the stator teeth. The slot fill factor of the stator slots is limited by the structure, and the amount of copper wire filling is strictly constrained, resulting in a ceiling for increasing the motor's magnetic flux. It is impossible to further increase the output torque by increasing the magnetic flux. At the same time, the winding process of axial flux motors is complex. The multi-winding assembly structure requires high-precision winding equipment, resulting in low production efficiency. Furthermore, the dense arrangement of windings leads to poor heat dissipation, which can easily cause excessive temperature rise during long-term operation, affecting the motor's service life and operational stability.

[0004] Meanwhile, traditional coreless motors generate magnetic fields only through coils, and the rotor magnets only participate in torque output with a single pole. The utilization rate of the magnets is low, and the rotor outer diameter is less restricted by the structure, resulting in a short torque lever arm, which further limits the torque increase. Conventional transverse flux motors are mostly designed for large sizes, and their structures cannot be adapted to the installation requirements of small sizes. There is no publicly available transverse flux motor structure suitable for small sizes. Summary of the Invention

[0005] This invention addresses the shortcomings of existing technologies, such as insufficient torque in micro-sized motors, low slot fill factor in transverse flux motors, and complex winding, by providing a micro-sized transverse flux motor.

[0006] This invention is achieved through the following technical solution:

[0007] A miniature transverse flux motor includes a motor housing and an electromagnetic core assembly disposed inside the motor housing. The electromagnetic core assembly includes a first stator core, a second stator core, and a magnetic ring disposed between the first stator core and the second stator core.

[0008] An air gap is provided between the first stator core, the second stator core and the magnetic ring. The first stator core and the second stator core each include several horseshoe-shaped stator blocks distributed in a circular shape. Each stator core is provided with a coil winding. The winding process of a single coil winding is simple, which greatly simplifies the production process and improves production efficiency. In addition, the independently arranged coil windings, together with the segmented stator, increase the contact area between the coil windings and the air, thereby improving the heat dissipation effect of the coil windings.

[0009] The magnetic ring includes a rotor body, a rotating shaft, and permanent magnets. The rotating shaft is coaxially fixed at the center of the rotor body. The permanent magnets are evenly distributed at equal angles along the circumference of the rotor body. The number of permanent magnets is twice the number of stator blocks in a single stator core. Both the upper and lower surfaces of the permanent magnets are magnetic pole working surfaces that cooperate with the stator core.

[0010] In a preferred embodiment of the present invention, the air gap spacing is 0.5mm-2mm to ensure the flexible rotation of the magnetic ring and avoid friction with the first stator core and the second stator core during rotation.

[0011] In a preferred embodiment of the present invention, each stator block is provided with a wire-insertion groove and a slot, the slot and the wire-insertion groove are connected, the coil winding is located in the wire-insertion groove, the wire-insertion groove provides installation space for the coil winding, and the slot is provided to facilitate the winding operation of the coil winding.

[0012] In a preferred embodiment of the present invention, the winding slot is opened along the diameter direction of the first stator core and the second stator core, and can be opened according to the copper wire requirements in the coil winding. Compared with the traditional stator tooth structure, it can fill more copper wire, effectively improve the magnetic flux, and thus improve the motor output torque and torque density.

[0013] In a preferred embodiment of the present invention, multiple permanent magnets are arranged on the circumference of the rotor body in an alternating manner of S pole and N pole, and the upper and lower magnetic pole working surfaces of the permanent magnets are respectively arranged opposite to the slots on the first stator core and the second stator core, so that both poles of the permanent magnets participate in torque output, greatly improving the utilization rate of the permanent magnets.

[0014] In a preferred embodiment of the present invention, the stator blocks in the first stator core and the second stator core are both made of soft magnetic material, and the stator blocks in the first stator core and the second stator core are staggered vertically, so that the stator core has excellent magnetic permeability, which can effectively enhance the magnetic field of the coil winding and improve the magnetic field strength.

[0015] In a preferred embodiment of the present invention, the motor housing includes a front cover and a rear cover, which are fastened together to form a mounting cavity, and the electromagnetic core component is located in the mounting cavity and is coaxially arranged with the mounting cavity.

[0016] In a preferred embodiment of the present invention, the first stator core and the second stator core are respectively fixed inside the front end cover and the rear end cover, and bearings are provided inside the front end cover and the rear end cover, and the rotating shaft is rotatably connected to the front end cover and the rear end cover through the bearings.

[0017] The beneficial effects of this invention are:

[0018] 1. This invention employs a transverse magnetic flux structure with upper and lower double stators and a central magnetic ring. The number of permanent magnets on the magnetic ring is twice the number of stator blocks in a single stator core. Both the upper and lower surfaces of the permanent magnets are designed as magnetic pole working surfaces, which cooperate with the stator cores on the upper and lower sides respectively. This allows both poles of the permanent magnets to participate in torque output. During operation, it is equivalent to two sets of motors working together, which enables a significant increase in motor output torque under the structural limitations of a small size. This effectively solves the problem of insufficient torque in existing small-size stepper motors and coreless motors.

[0019] 2. The stator core in this invention adopts a segmented horseshoe structure, and a wire-inserting slot is opened on each stator block. The size of the wire-inserting slot can be flexibly increased according to the filling requirements of the coil winding, so that more coils can be filled. This breaks through the constraint of the stator slot full rate of conventional axial flux motors, effectively improves the internal magnetic flux of the motor, and thus significantly improves the torque density of the motor, allowing the overall volume of the motor to be further compressed under the same output torque requirements.

[0020] 3. In this invention, only one coil winding is configured in one stator core, which eliminates the complex process of traditional multi-winding and assembly, greatly simplifies the winding process in motor production, improves the overall production efficiency of motor, and at the same time, setting a single coil winding in one stator core increases the contact area between the coil winding and the air, thereby improving the heat dissipation effect of the coil winding, effectively reducing the temperature rise during motor operation, and improving the stability and service life of motor operation. Attached Figure Description

[0021] Figure 1 This is a three-dimensional structural diagram of the electromagnetic core component in a miniature transverse flux motor according to the present invention.

[0022] Figure 2 This is a three-dimensional structural diagram of the stator core in a miniature transverse flux motor according to the present invention.

[0023] Figure 3 This is a schematic diagram of the stator core and coil windings in a miniature transverse flux motor according to the present invention;

[0024] Figure 4 This is a schematic diagram of the structure of a magnetic ring in a miniature transverse flux motor according to the present invention;

[0025] Figure 5 This is a cross-sectional view of a miniature transverse flux motor according to the present invention.

[0026] In the diagram: 1. Motor housing; 11. Front cover; 12. Rear cover; 2. Electromagnetic core assembly; 21. First stator core; 22. Second stator core; 23. Magnetic ring; 231. Rotor body; 232. Shaft; 233. Permanent magnet; 24. Coil winding; 25. Stator block; 26. Wire slot; 27. Slot. Detailed Implementation

[0027] The preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, so that the advantages and features of the present invention can be more easily understood by those skilled in the art, thereby providing a clearer and more definite definition of the scope of protection of the present invention. The directional terms used in this invention, such as "up," "down," "front," "back," "left," "right," "top," and "bottom," are merely for reference to the accompanying drawings. Therefore, the directional terms used are for illustrating and understanding the present invention, and not for limiting the present invention.

[0028] like Figure 1-5 The present invention relates to a miniature transverse flux motor, comprising a motor housing 1 and an electromagnetic core component 2 disposed inside the motor housing 1. The motor housing 1 includes a front cover 11 and a rear cover 12, which are fastened together to form a mounting cavity. The internal space of the mounting cavity is adapted to the shape of the electromagnetic core component 2, and the electromagnetic core component 2 is located in the mounting cavity and is coaxially disposed with the mounting cavity.

[0029] The electromagnetic core component 2 includes a first stator core 21, a second stator core 22, and a magnetic ring 23 disposed between the first stator core 21 and the second stator core 22.

[0030] An air gap of 0.5mm-2mm is provided between the first stator core 21, the second stator core 22 and the magnetic ring 23. This gap can ensure the flexible rotation of the magnetic ring 23 and avoid friction with the first stator core 21 and the second stator core 22 during rotation, while maintaining efficient magnetic coupling and avoiding excessive magnetic circuit loss.

[0031] Specifically, the first stator core 21 and the second stator core 22 have the same structure. Both are composed of several stator blocks 25 evenly distributed along the circumference. The stator blocks 25 have a horseshoe-shaped structure, which has good magnetic conductivity and magnetic concentration capabilities. The horseshoe-shaped structure is specifically presented in that each stator block 25 has a wire-inserting groove 26 and a slot 27. The wire-inserting groove 26 provides installation and positioning space for the coil winding 24. The wire-inserting groove 26 is opened along the diameter direction of the stator core and can be opened according to the amount of copper wire required in the coil winding 24. Compared with the traditional stator tooth structure, it can fill more copper wire, effectively improve the magnetic flux, and thus improve the motor output torque and torque density. In addition, the slot 27 and the wire-inserting groove 26 are interconnected. The setting of the slot 27 facilitates the winding operation of the coil winding 24.

[0032] Each stator core is equipped with a coil winding 24. The winding process of a single coil winding 24 is simple, which greatly simplifies the production process and improves production efficiency. In addition, the independently arranged coil windings 24, together with the segmented stator, increase the contact area between the coil windings 24 and the air, thereby improving the heat dissipation effect of the coil windings 24.

[0033] The first stator core 21 and the second stator core 22 are respectively installed on the inner sidewalls of the front end cover 11 and the rear end cover 12. The stator blocks 25 in the first stator core 21 and the stator blocks 25 in the second stator core 22 are arranged in an up-down staggered manner when fixed, which is beneficial to optimize the air gap magnetic field distribution, reduce torque pulsation, and improve running stability. In addition, the stator blocks 25 are made of soft magnetic material, which can effectively enhance the magnetic field generated by the coil winding 24 and improve the electromagnetic conversion efficiency.

[0034] The magnetic ring 23 includes a rotor body 231, a rotating shaft 232 and a permanent magnet 233. The rotating shaft 232 is coaxially fixed to the center of the rotor body 231. Bearings are installed at the center of the front end cover 11 and the rear end cover 12. The two ends of the rotating shaft 232 are respectively connected to the corresponding bearings.

[0035] Multiple permanent magnets 233 are evenly distributed at equal angles along the circumference of the rotor body 231. The permanent magnets 233 are arranged in an alternating manner of S pole and N pole on the circumference of the rotor body 231. The number of permanent magnets 233 is twice the number of stator blocks 25 in a single stator core. The upper and lower surfaces of the permanent magnets 233 are magnetic pole working surfaces that cooperate with the stator core. The upper magnetic pole working surface is opposite to the slot 27 on the first stator core 21, and the lower magnetic pole working surface is opposite to the slot 27 on the second stator core 22. This allows both poles of the permanent magnets 233 to participate in torque output, greatly improving the utilization rate of the permanent magnets 233.

[0036] In this embodiment, a transverse magnetic flux structure is adopted, with the magnetic field direction perpendicular to the rotation direction of the magnetic ring 23. After energization, the current generates a circumferential magnetic field around the coil winding 24. The magnetic field is conducted and enhanced through the horseshoe-shaped stator block 25, forming a periodically alternating magnetic field on the side of the stator block 25 facing the magnetic ring 23. At the same time, the number of permanent magnets 233 on the magnetic ring 23 is twice the number of stator blocks 25 in a single stator core, and they are evenly distributed along the circumference with alternating N and S poles. This causes the magnetic fields generated by the first stator core 21 and the second stator core 22 to interact with the magnetic field of the permanent magnets 233. According to the principle of minimum magnetic reluctance, the alternating magnetic fields generated by the first stator core 21 and the second stator core 22 form a continuous attractive and repulsive force on the permanent magnets 233, thereby driving the magnetic ring 23 to rotate continuously and converting electrical energy into mechanical energy.

[0037] Meanwhile, due to the adoption of a dual-stator structure, the permanent magnet 233 is driven by the first stator core 21 and the second stator core 22 simultaneously, which is equivalent to two sets of motor units working synchronously, thereby significantly improving the output torque of the motor. In addition, the design of one coil winding 24 in a single stator core can increase the space of the winding slot 26 and increase the amount of copper wire filling, thereby improving the magnetic flux and torque density. At the same time, it simplifies the winding process and improves the heat dissipation effect of the coil winding 24, so that the motor still has high torque and high efficiency performance in a small size.

[0038] It should be noted that the parts not covered in this invention are the same as or can be implemented using existing technologies; the various drives in this invention can be implemented using corresponding power structures such as cylinders, hydraulic cylinders, electric cylinders, and motors in conjunction with connecting rods, guide rods, etc., and are not limited to the structures described in the specification and the drawings.

[0039] In the description of the embodiments of the present invention, unless otherwise expressly specified and limited, the terms "installed," "connected," "linked," "set up," "equipped with," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in the present invention based on the specific circumstances.

[0040] The embodiments described above are merely examples of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention.

Claims

1. A miniature transverse flux motor, comprising a motor housing (1) and an electromagnetic core assembly (2) disposed inside the motor housing (1), characterized in that: The electromagnetic core component (2) includes a first stator core (21), a second stator core (22) and a magnetic ring (23) disposed between the first stator core (21) and the second stator core (22); An air gap is provided between the first stator core (21), the second stator core (22) and the magnetic ring (23), and the first stator core (21) and the second stator core (22) each include several stator blocks (25) with a circular distribution of horseshoe-shaped structures, and each stator core is provided with a coil winding (24). The magnetic ring (23) includes a rotor body (231), a rotating shaft (232) and a permanent magnet (233). The rotating shaft (232) is coaxially fixed at the center of the rotor body (231). The permanent magnets (233) are evenly distributed at equal angles along the circumference of the rotor body (231). The number of permanent magnets (233) is twice the number of stator blocks (25) in a single stator core. The upper and lower surfaces of the permanent magnets (233) are both magnetic pole working surfaces.

2. The miniature transverse flux motor according to claim 1, characterized in that: The spacing of the air gap is 0.5mm-2mm.

3. A miniature transverse flux motor according to claim 1, characterized in that: Each stator block (25) is provided with a wire-insertion groove (26) and a slot (27), the slot (27) and the wire-insertion groove (26) are connected, and the coil winding (24) is located in the wire-insertion groove (26).

4. A miniature transverse flux motor according to claim 3, characterized in that: The winding groove (26) is opened along the diameter direction of the first stator core (21) and the second stator core (22).

5. A miniature transverse flux motor according to claim 3, characterized in that: Multiple permanent magnets (233) are arranged on the circumference of the rotor body (231) in an alternating manner of S pole and N pole, and the upper and lower magnetic pole working surfaces of the permanent magnets (233) are respectively set opposite to the slots (27) on the first stator core (21) and the second stator core (22).

6. A miniature transverse flux motor according to claim 5, characterized in that: The stator blocks (25) in the first stator core (21) and the second stator core (22) are both made of soft magnetic material, and the stator blocks (25) in the first stator core (21) and the second stator core (22) are staggered vertically.

7. A miniature transverse flux motor according to claim 1, characterized in that: The motor housing (1) includes a front cover (11) and a rear cover (12). The front cover (11) and the rear cover (12) are fastened together to form an installation cavity. The electromagnetic core component (2) is located in the installation cavity and is coaxially arranged with the installation cavity.

8. A miniature transverse flux motor according to claim 6, characterized in that: The first stator core (21) and the second stator core (22) are respectively fixed inside the front end cover (11) and the rear end cover (12), and the front end cover (11) and the rear end cover (12) are both provided with bearings. The rotating shaft (232) is rotatably connected to the front end cover (11) and the rear end cover (12) through the bearings.

Images