Axial flux motor adopting printed winding

Abstract

The utility model discloses an axial magnetic flux motor adopting a printed winding, which comprises a stator, the stator comprises a printed circuit board and a plurality of stator cores, the printed circuit board is formed by combining a plurality of PCB windings, a mounting hole is arranged in the middle of each PCB winding, the stator cores are mounted in the mounting holes, the stator cores are formed by winding magnetic conductive amorphous materials, and the printed circuit board and the stator cores are arranged in the mounting holes. After the stator core is arranged in the center of the coil, the equivalent air gap is the physical air gap, the magnetic resistance is small, the power density is high, materials can be greatly saved, the power density is improved, the stator core made of the magnetic conductive amorphous material greatly simplifies the processing and manufacturing process of the motor, and the stator core is greatly helpful for batch production of the motor. In addition, the coil does not face the alternating magnetic field of the air gap in the main magnetic circuit, the eddy current on the coil is inhibited, the efficiency is ensured, the stator core is formed by winding the amorphous material, the amorphous material can meet the high-frequency occasion, the iron loss at high speed and high frequency is very small, and the high-speed efficiency of the motor can be well ensured.

Description

Technical Field

[0001] The utility model relates to an axial flux motor using a printed winding. Background Art

[0002] The axial flux motor with printed winding is the flagship product of Infinitum Electric. Its structure adopts printed winding technology, the stator is composed of printed winding, and the motor structure is a kind of axial flux motor or disc motor. It has no stator core, and the main magnetic field path is magnetic tile, air gap, winding, rotor core, etc., forming a loop. However, there are still problems or defects in this structure: although the axial dimension of this structure is short, the PCB board is not magnetic, and its magnetic permeability is equivalent to the air gap, resulting in the total air gap of the motor being equivalent to the sum of two parts: PCB winding and physical air gap. A larger air gap means a larger magnetic resistance, and the motor magnetic field is seriously lost in the air gap. Due to the limited output capacity of the motor, the output torque can only be increased by increasing the number of layers of the PCB winding, but increasing the number of layers of the PCB winding means that the axial dimension occupied by the PCB winding is increased, and the equivalent air gap will also increase. When designing the PCB winding, the cross-sectional area of ​​its copper cladding is highly correlated with the efficiency. The larger the equivalent cross-sectional area, the smaller its resistance and the higher the efficiency. There are two ways to increase the cross-sectional area: increasing the thickness and increasing the width. Increasing the thickness will increase the thickness of the PCB board and increase the equivalent air gap. When increasing the width, since the main magnetic field directly passes through the winding, the winding is a conductive material, cutting the magnetic flux lines will generate eddy currents inside the winding, which will seriously affect the efficiency at high frequencies. Summary of the invention

[0003] The utility model aims to provide an axial flux motor with printed windings, so as to solve the technical problem that in the prior art axial flux motor with printed windings, since the PCB board is not magnetically conductive, its magnetic permeability is equivalent to the air gap, resulting in that the total air gap of the motor can be equivalent to the sum of two parts, namely, there are PCB windings and physical air gaps. A larger air gap means a larger magnetic resistance, and the motor magnetic field is seriously lost in the air gap. When the width is increased, since the main magnetic field directly passes through the winding, the winding is a conductive material, and cutting the magnetic flux lines will generate eddy currents inside the winding, which will seriously affect the efficiency at high frequencies.

[0004] The technical solution of the utility model is achieved in this way:

[0005] An axial flux motor using printed windings includes a stator, characterized in that the stator includes a printed circuit board and a plurality of stator cores, a plurality of groups of PCB windings are arranged circumferentially on the printed circuit board, a mounting hole is provided in the middle of each group of PCB windings, the stator core is nested and installed in the mounting hole, and the stator core is wound by a magnetically conductive amorphous material.

[0006] The two ends of each stator core protrude from the two end surfaces of the printed circuit board respectively.

[0007] The above-mentioned axial flux motor further comprises a rotor, which comprises a first rotor component and a second rotor component, and the first rotor component and the second rotor component are respectively arranged on both end surfaces of the printed circuit board.

[0008] The first rotor assembly and the second rotor assembly adopt the same rotor structure and are arranged on both end surfaces of the printed circuit board in the same direction.

[0009] The above-mentioned first rotor assembly and second rotor assembly both include a plurality of magnetic tiles and a rotor core. The plurality of magnetic tiles are circumferentially spaced apart on the end surface of the rotor core. During installation, the magnetic tiles of the first rotor assembly and the second rotor assembly are respectively close to the two ends of the stator core, and there is a gap between the magnetic tiles and the stator core to form an air gap.

[0010] The rotor core can be made of silicon steel sheets, composite materials or SMC materials.

[0011] The shape of the magnetic tile can be fan-shaped, rectangular, rhombus-shaped, tile-shaped or trapezoidal.

[0012] The above-mentioned magnetic tile is in the shape of a sector, and the sector-shaped magnetic tile is composed of a plurality of small magnetic tiles or a whole sector-shaped magnetic tile.

[0013] The fan-shaped magnetic tiles are composed of several small magnetic tile blocks. When the centers of several small magnetic tile blocks are on the same center line, the fan-shaped magnetic tiles are non-oblique-pole magnetic tiles; when the centers of several small magnetic tile blocks are not on the same center line, the fan-shaped magnetic tiles are oblique-pole magnetic tiles.

[0014] The above-mentioned axial flux motor also includes a casing assembly, and the stator and the rotor are installed in the cavity of the casing assembly.

[0015] The above-mentioned PCB windings are copper-clad on a printed circuit board and distributed according to the corresponding motor phase sequence, and a mounting hole is arranged in the middle of each PCB winding.

[0016] Compared with the prior art, the utility model has the following advantages:

[0017] 1. The utility model includes a stator, which includes a printed circuit board and a plurality of stator cores. The printed circuit board is composed of a plurality of PCB windings. A mounting hole is provided in the middle of each PCB winding. The stator core is mounted in the mounting hole. The stator core is wound with a magnetically conductive amorphous material. After the stator core is arranged at the center of the coil, its equivalent air gap is its physical air gap. The magnetic resistance is small and the power density is high, which can greatly save materials and improve the power density. The stator core made of magnetically conductive amorphous material greatly simplifies the processing and manufacturing process of the motor, which is of great help to the mass production of the motor. In addition, the PCB winding does not directly face the alternating magnetic field of the air gap in the main magnetic circuit, and the eddy current on the PCB winding is suppressed, so that the efficiency is guaranteed. In addition, the stator core is wound with amorphous material, which can meet high-frequency occasions, and the iron loss at high speed and high frequency is very small, which can well ensure the high-speed efficiency of the motor.

[0018] 2. Other advantages of the utility model are described in detail in the embodiment section of the specification. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 A three-dimensional diagram provided for the utility model;

[0020] Figure 2 A partial exploded view provided for the utility model;

[0021] Figure 3 An exploded view provided for the utility model;

[0022] Figure 4 A front view provided for the utility model;

[0023] Figure 5 for Figure 4 Middle AA section view;

[0024] Figure 6 for Figure 5 A partial enlarged view of B. DETAILED DESCRIPTION

[0025] In order to make the purpose, technical solution and advantages of the embodiment of the utility model clearer, the technical solution in the embodiment of the utility model will be clearly and completely described below in conjunction with the drawings in the embodiment of the utility model. Obviously, the described embodiment is a part of the embodiment of the utility model, not all of the embodiments. Based on the embodiment of the utility model, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the utility model.

[0026] Embodiment 1:

[0027] like Figures 1 to 6As shown, this embodiment provides an axial flux motor using printed windings, including a stator 1, characterized in that: the stator 1 includes a printed circuit board 11 and a plurality of stator cores 12, a plurality of groups of PCB windings 111 are arranged circumferentially on the printed circuit board 11, a mounting hole 112 is provided in the middle of each group of PCB windings 111, and the stator core 12 is nested and installed in the mounting hole 112, the stator core 12 is wound by a magnetically conductive amorphous material, after the stator core is arranged at the center of the coil, its equivalent air gap is its physical air gap, the magnetic resistance is small, the power density is high, the material can be greatly saved, and the power density can be improved, the stator core made of a magnetically conductive amorphous material greatly simplifies the processing and manufacturing process of the motor, and is of great help to the mass production of the motor, in addition, the PCB winding 111 does not directly face the alternating magnetic field of the air gap in the main magnetic circuit, the eddy current on the PCB winding 111 is suppressed, and the efficiency is guaranteed, in addition, the stator core is wound by amorphous material, the amorphous material can meet the high-frequency occasions, the iron loss at high speed and high frequency is very small, and the high-speed efficiency of the motor can be well guaranteed.

[0028] The two ends of each stator core 12 protrude from the two end surfaces of the printed circuit board 11 respectively. Since its main magnetic circuit is on the stator core 12, the thickness requirement of the printed circuit board 11 is low, which is more helpful for overall cost control. Too high process requirements for the printed circuit board 11 will greatly increase the cost; at the same time, its PCB winding does not directly face the air gap in the main magnetic circuit, and the alternating air gap magnetic field will not generate eddy currents on the winding, and the eddy current loss of the winding is suppressed.

[0029] The above also includes a rotor 2, which includes a first rotor component 21 and a second rotor component 22. The first rotor component 21 and the second rotor component 22 are respectively arranged on both end surfaces of the printed circuit board 11, and the structural arrangement is reasonable.

[0030] The first rotor assembly 21 and the second rotor assembly 22 described above adopt the same rotor structure and are arranged on both end surfaces of the printed circuit board 11 in the same direction.

[0031] The above-mentioned first rotor assembly 21 and second rotor assembly 22 both include a plurality of magnetic tiles 201 and a rotor core 202. The plurality of magnetic tiles 201 are circumferentially spaced apart on the end surface of the rotor core 202. During installation, the magnetic tiles 201 of the first rotor assembly 21 and the second rotor assembly 22 are close to the stator core 12, and there is a gap between the magnetic tiles 201 and the stator core 12 to form an air gap.

[0032] The rotor core 202 may be made of silicon steel sheets, composite materials or SMC materials.

[0033] The shape of the magnetic tile 201 can be fan-shaped, rectangular, diamond-shaped, tile-shaped or trapezoidal.

[0034] The shape of the magnetic tile 201 is fan-shaped, and the fan-shaped magnetic tile is composed of a plurality of small magnetic tiles or a whole fan-shaped magnetic tile.

[0035] The above-mentioned fan-shaped magnetic tile 201 is composed of a plurality of small magnetic tile blocks. When the centers of the plurality of small magnetic tile blocks are on the same center line, the fan-shaped magnetic tile 201 is a non-slant-pole magnetic tile; when the centers of the plurality of small magnetic tile blocks are not on the same center line, the fan-shaped magnetic tile 201 is a slant-pole magnetic tile. In this solution, the fan-shaped magnetic tile is a slant-pole magnetic tile, which is the best solution.

[0036] The above also includes a casing assembly, and the stator 1 and the rotor 2 are installed in the cavity of the casing assembly, and the structural arrangement is reasonable.

[0037] The above-mentioned PCB windings 111 are copper-clad on the printed circuit board 11 and are distributed according to the corresponding motor phase sequence. A mounting hole 112 is arranged in the middle of each PCB winding 111 .

[0038] A stator core wound with an amorphous material can be arranged in the mounting hole 112 of the PCB winding 111. After using the stator core, the motor equivalent air gap is its physical air gap, which is much smaller than the equivalent air gap when only the PCB board is used in the traditional solution (in this case, the equivalent air gap = physical air gap + PCB thickness); the stator solution of the utility model can greatly reduce the amount of magnetic tiles, because its main magnetic circuit mainly passes through the stator core, and the magnetic resistance on the main magnetic circuit is small. Compared with the traditional solution of using only PCB, the volume required for the same torque is smaller;

[0039] In addition, since the main magnetic circuit is on the stator core, the thickness requirement of the printed circuit board 11 is low, which is more helpful for overall cost control. Too high PCB process requirements will greatly increase the cost. At the same time, the PCB winding 111 does not directly face the air gap in the main magnetic circuit, and the alternating air gap magnetic field will not generate eddy current on the PCB winding 111, so the eddy current loss of the winding is suppressed.

[0040] The stator core is formed by winding amorphous materials. Amorphous materials can meet high-frequency occasions. The iron loss at high speed and high frequency is very small, which can well ensure the high-speed efficiency of the electric motor. The amorphous material stator core in this design can be processed as little as possible or processed as little as possible. It can be directly wound into shape by utilizing its ultra-thin and easy-to-wind characteristics and put into the PCB board for use as an iron core.

[0041] The rotor core material can be various materials, including silicon steel sheets, composite materials, SMC materials, etc.

[0042] Theoretical analysis of the utility model: The PCB winding of the conventional axial flux motor using printed winding is directly in the alternating air gap magnetic field, generating eddy currents on the conductor (here refers to the winding or copper coating on the circuit board). This part of the eddy current has no practical value and will bring additional losses. Since the printed winding is almost all copper coating on the PCB (serving as the stator winding), the influence of eddy currents is very large.

[0043] However, in the utility model, a mounting hole 112 is provided in the middle of each group of PCB windings 111, and the stator core 12 is nested and installed in the mounting hole 112. The stator core 12 is wound by a magnetically conductive amorphous material. The stator core 12 directly faces the air gap magnetic field, and the main magnetic circuit passes through the stator core 12, and the eddy current loss on the winding or copper cladding is suppressed.

[0044] Since the coercive force of the magnetic amorphous material is very low, the loss when the magnetic field changes is very small, and its hysteresis loss is very small; since the amorphous material is very thin (the thickness is only 1 / 19 of the conventional silicon steel sheet), the equivalent resistance is very large, and the eddy current loss will be very small. A comparison of the same situation found that the torque output of the axial flux motor with printed windings using amorphous materials and the axial flux motor with simple PCB windings differed by about 6.8 times. The magnetic amorphous material can be processed into any material and can be selected according to the actual size, space and needs, which greatly provides the design versatility of the solution. Even some irregular shapes can be filled with iron cores. The extremely high hardness and difficult processing of amorphous materials are minimized. The incoming material is originally a strip material, which can be directly wound into an iron core for use. The advantages of magnetic amorphous materials in this type of motor are magnified, and they are perfectly adapted to the axial flux motor with printed windings. Due to its small thickness (generally 0.5mm for silicon steel sheets and 0.026mm for amorphous materials), the eddy current loss at high speed and high frequency is very small; due to its low coercive force, the hysteresis loss at high speed and high frequency is also very small. However, it can provide a magnetic conductivity far exceeding that of an air gap or a PCB board.

[0045] The above embodiments are preferred implementation modes of the present invention, but the implementation modes of the present invention are not limited thereto. Any other changes, modifications, substitutions, combinations, and simplifications made without departing from the spirit and principle of the present invention are equivalent replacement methods and are included in the protection scope of the present invention.

Claims

1. An axial flux motor using printed windings, comprising a stator (1), characterized in that: The stator (1) comprises a printed circuit board (11) and a plurality of stator cores (12); a plurality of groups of PCB windings (111) are arranged circumferentially on the printed circuit board (11); a mounting hole (112) is provided in the middle of each group of PCB windings (111); the stator core (12) is nested and mounted in the mounting hole (112); and the stator core (12) is formed by winding a magnetically conductive amorphous material.

2. The axial flux motor using printed windings according to claim 1, characterized in that: Two ends of each stator core (12) protrude from two end surfaces of the printed circuit board (11) respectively.

3. An axial flux motor using printed windings according to claim 1 or 2, characterized in that: It also includes a rotor (2), which includes a first rotor component (21) and a second rotor component (22), and the first rotor component (21) and the second rotor component (22) are respectively arranged on both end surfaces of the printed circuit board (11).

4. The axial flux motor using printed windings according to claim 3, characterized in that: The first rotor assembly (21) and the second rotor assembly (22) adopt rotor structures with the same structure and are arranged in the same direction on both end surfaces of the printed circuit board (11).

5. The axial flux motor using printed windings according to claim 4, characterized in that: The first rotor assembly (21) and the second rotor assembly (22) both comprise a plurality of magnetic tiles (201) and a rotor core (202). The plurality of magnetic tiles (201) are circumferentially spaced apart and arranged on the end surface of the rotor core (202). When installed, the magnetic tiles (201) of the first rotor assembly (21) and the second rotor assembly (22) are respectively close to the two ends of the stator core (12), and a gap exists between the magnetic tiles (201) and the stator core (12) to form an air gap.

6. The axial flux motor using printed windings according to claim 5, characterized in that: The rotor core (202) can be made of silicon steel sheets, composite materials or SMC materials.

7. The axial flux motor using printed windings according to claim 6, characterized in that: The shape of the magnetic tile (201) can be fan-shaped, rectangular, rhombus-shaped, tile-shaped or trapezoidal.

8. The axial flux motor using printed windings according to claim 7, characterized in that: The shape of the magnetic tile (201) is fan-shaped, and the fan-shaped magnetic tile (201) is composed of a plurality of small magnetic tiles or a whole fan-shaped magnetic tile.

9. The axial flux motor using printed windings according to claim 8, characterized in that: The fan-shaped magnetic tile (201) is composed of a plurality of small magnetic tile blocks. When the centers of the plurality of small magnetic tile blocks are on the same center line, the fan-shaped magnetic tile (201) is a non-oblique-pole magnetic tile; when the centers of the plurality of small magnetic tile blocks are not on the same center line, the fan-shaped magnetic tile (201) is an oblique-pole magnetic tile.

10. The axial flux motor using printed windings according to claim 3, characterized in that: It also includes a casing assembly, in which the stator (1) and the rotor (2) are installed in the cavity of the casing assembly.

11. An axial flux motor using printed windings according to claim 1 or 2, characterized in that: The PCB windings (111) are copper-clad on a printed circuit board (11) and are distributed according to the corresponding motor phase sequence, and a mounting hole (112) is arranged in the middle of each PCB winding (111).

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