Axial magnetic flux double-rotor PCB motor for sweeping robot

Abstract

The utility model discloses an axial magnetic flux double-rotor PCB motor for a sweeping robot, and relates to the technical field of motor manufacturing, the axial magnetic flux double-rotor PCB motor comprises a volute and a PCB stator fixed in the volute, one end of the volute is provided with an end cover matched with the volute, and a rotating shaft is rotatably arranged between the volute and the end cover and penetrates through the PCB stator in the axial direction of the PCB stator; the PCB stator comprises a plurality of PCBs which are stacked in the unique direction and welded in parallel, the PCBs are provided with a plurality of winding coils in the circumferential direction, and two rotors are fixedly connected to the two ends, away from the PCBs, of the rotating shaft; a plurality of magnetic sheets are arranged at the end, facing the PCB stator, of the rotor, a fan cover is arranged opposite to the volute, and a movable impeller fixedly connected with the rotating shaft is rotationally arranged in the fan cover. A plurality of PCBs are overlapped and welded to form the parallel PCB stator, a stator assembly wound on a stator iron core is replaced, the PCB stator has no iron core and has a complicated winding process, the manufacturing efficiency is high, the yield of finished products is extremely high, motor parameters are stable, and the consistency is relatively good.

Description

Technical Field

[0001] This application relates to the field of motor manufacturing technology, and in particular to an axial flux dual-rotor PCB motor for a sweeping robot. Background Technology

[0002] Traditional robotic vacuum cleaners typically use external rotor motors. The stator core of a traditional external rotor motor is made of silicon steel sheets through stamping and riveting. After the core is coated with insulation or plastic-coated, the winding coils are wound. The wound coils require manual processing of the joints and welding of the lead-out terminals.

[0003] Regarding the aforementioned technologies, the inventors believe that the winding process on the stator core is complex, and the winding machine needs to be precisely designed and controlled; otherwise, it will lead to poor insulation of the winding coil and a high manufacturing defect rate. Utility Model Content

[0004] The purpose of this application is to provide an axial flux dual-rotor PCB motor for a sweeping robot, in order to improve the problem that the winding process on the stator core is complicated and the winding machine needs to be precisely designed and controlled, otherwise it will lead to poor insulation of the winding coil and high manufacturing defect rate.

[0005] This application provides an axial flux dual-rotor PCB motor for a robotic vacuum cleaner, which adopts the following technical solution:

[0006] A dual-rotor PCB motor with axial flux for a robotic vacuum cleaner includes a volute and a PCB stator fixed within the volute. One end of the volute is fitted with an end cap that mates with the volute. A rotating shaft is rotatably disposed between the volute and the end cap, passing through the PCB stator along the axial direction. The PCB stator comprises several PCB boards stacked and welded in parallel along a single direction. Several winding coils are arranged on the PCB boards along the circumferential direction. Rotors are fixedly connected to the two ends of the rotating shaft away from the PCB boards. Several magnetic plates are disposed at the end of the rotor facing the PCB stator. A fan shroud is disposed opposite to the volute, and a moving impeller fixedly connected to the rotating shaft is rotatably disposed within the fan shroud.

[0007] By adopting the above technical solution, several winding coils are set on the PCB board. Several PCB boards are stacked and welded in parallel along a single direction to form a PCB stator, which replaces the stator assembly formed by winding wire on the stator core. The rotors at both ends of the PCB stator are arranged opposite each other. On the circumferential direction of the rotor near the PCB stator, magnetic sheets are alternately arranged with N and S poles. The N and S poles on the two rotors are distributed opposite each other. The magnetic fields generated by the magnetic poles of the PCB stator and the rotor cut each other, generating torque on the rotor, causing the rotating shaft to rotate and drive the impeller to rotate to draw air. The PCB stator does not have an iron core or a complicated winding manufacturing process, resulting in high manufacturing efficiency, extremely high yield of finished products, stable motor parameters, and good consistency.

[0008] Optionally, the PCB board has several mounting holes at its edge that communicate with the stacked PCB boards, and the mounting holes are used to insert connecting screws to fix adjacent PCB boards.

[0009] By adopting the above technical solution, mounting holes are opened at the edge of the PCB board, and connecting screws are inserted into the mounting holes to fix several PCB boards stacked together, reducing the possibility of misalignment of winding coils between adjacent PCB boards.

[0010] Optionally, the PCB board has a connecting hole along the axial direction, and the inner diameter of the connecting hole is larger than the outer diameter of the rotating shaft.

[0011] By adopting the above technical solution, the inner diameter of the connecting hole on the PCB board is larger than the outer diameter of the rotating shaft, so as to prevent the rotating shaft from rubbing against the PCB board during rotation and affecting the PCB board.

[0012] Optionally, the inner wall of the volute is provided with a limiting step that abuts against the PCB board. The inner diameter of the end cap at the step position is smaller than the inner diameter of the volute, and the side of the end cap facing the volute abuts against the PCB board.

[0013] By adopting the above technical solution, the limiting step on the inner sidewall of the volute abuts against the PCB board, and the side of the end cover facing the volute abuts against the PCB board, thus fixing the PCB stator composed of the stacked PCB boards and preventing the PCB stator from changing position in the volute and rubbing against the rotor as much as possible.

[0014] Optionally, the outer diameter of the PCB board matches the inner diameter of the volute.

[0015] By adopting the above technical solution, the outer diameter of the PCB board is matched with the inner diameter of the volute, so as to minimize the rotation of the PCB board in the volute.

[0016] Optionally, the PCB board has connection holes at the beginning and end of the winding coil, and the multi-layer winding coils in the PCB board are connected in parallel through the connection holes.

[0017] By adopting the above technical solution, connection holes are opened at the beginning and end of the winding coil on the PCB board, which facilitates the parallel connection of the multi-layer coils in the PCB board through the connection holes. Adjacent PCB boards are connected by parallel welding through the outermost adjacent three-phase solder pad holes.

[0018] Optionally, the winding coils located on the surface of the PCB are distributed in a three-phase symmetrical manner.

[0019] By adopting the above technical solution, several winding coils located on the surface of the PCB board are distributed in a three-phase symmetrical manner. The multi-layer PCB boards are stacked together in parallel or series to form a three-phase symmetrical winding structure. When appropriate current is applied to the three-phase windings respectively, according to the Faraday electromagnetic induction principle, the magnetic fields generated by the stator and rotor magnetic poles cut each other, generating torque on the rotor and thus driving the rotating shaft to rotate.

[0020] Optionally, the PCB board is provided with jumper lines communicating with the connection holes, and the jumper lines connect the three-phase distributed winding coils.

[0021] By adopting the above technical solution, a jumper line connected to the connection hole is provided on the PCB board. The jumper line facilitates the connection of the three-phase distributed winding coils on the PCB board to form a three-phase winding structure.

[0022] In summary, this application includes at least one of the following beneficial technical effects:

[0023] 1. Several winding coils are set on the PCB board. The PCB stator is formed by stacking several PCB boards to replace the stator formed by winding on the stator core. The PCB stator has no core and no complicated winding manufacturing process. It has high manufacturing efficiency, extremely high yield rate of finished products, stable motor parameters and good consistency.

[0024] 2. The circumferential sidewall of the PCB board fits against the inner sidewall of the end cover, the limiting step of the inner sidewall of the end cover abuts against the PCB board, and the side of the volute facing the end cover abuts against the PCB board, thus fixing the PCB stator composed of the stacked PCB boards and preventing the PCB stator from changing position in the volute and colliding with the rotor as much as possible.

[0025] 3. Connecting holes are made at the beginning and end of the coil on the PCB board to connect multiple layers of coils in parallel on a single PCB board. Adjacent PCB boards are connected by parallel soldering through the outermost adjacent three-phase pad holes. Attached Figure Description

[0026] Figure 1 This is an overall schematic diagram of an axial flux dual-rotor PCB motor used in a robotic vacuum cleaner.

[0027] Figure 2 This is a schematic diagram of the connections between printed winding coils on a PCB board.

[0028] In the diagram, 1. Volute; 11. Limiting step; 12. End cap; 2. PCB stator; 21. PCB board; 211. Mounting hole; 212. Connecting screw; 213. Connecting hole; 22. Winding coil; 23. Connecting hole; 24. Jumper wire; 25. Three-phase solder pad hole; 3. Rotating shaft; 4. Rotor; 41. Magnet; 5. Fan cover; 51. Moving impeller; 52. Air outlet; 53. Air inlet. Detailed Implementation

[0029] The following is in conjunction with the appendix Figure 1 -Appendix Figure 2 This application will be described in further detail below.

[0030] A dual-rotor PCB motor with axial flux for a robotic vacuum cleaner, referenced Figure 1 The system includes a volute 1 and a PCB stator 2 fixed within the volute 1. One end of the volute 1 has an end cap 12 that mates with it. The volute 1 and end cap 12 are engaged and fixed with screws. A rotating shaft 3 is axially inserted through the PCB stator 2 between the volute 1 and the end cap 12, rotating via a bearing. The PCB stator 2 includes several stacked PCB boards 21. In this embodiment, there are six PCB boards 21. One PCB board 21 has a drive circuit (not shown in the figure) mounted on it. Several winding coils 22 are printed on the PCB board 21 along its circumference. Rotors are fixedly connected to the two ends of the rotating shaft 3 away from the PCB board 21. 4. The rotor 4 is fixed to the rotating shaft 3 by a key connection. Several magnetic sheets 41 with alternating N and S poles are glued to the end of the rotor 4 facing the PCB stator 2. The magnetic sheets 41 are permanent magnets. The two rotors 4 are arranged in mirror symmetry. When the magnetic sheets 41 are glued, the N and S poles are arranged facing each other. The volute 1 is fixed with a fan shroud 5. The moving impeller 51, which is fixed to the rotating shaft 3 by an interference fit, is rotatably set in the fan shroud 5. The magnetic fields generated by the magnetic poles of the PCB stator 2 and the rotor 4 cut each other, generating torque on the rotor 4, causing the rotating shaft 3 to rotate and drive the moving impeller 51 to rotate, drawing air from the air inlet 53 of the fan shroud 5 and blowing the air out from the air outlet 52 of the fan shroud 5.

[0031] Reference Figure 1 and Figure 2 The PCB board 21 has several mounting holes 211 at its edge that communicate with the stacked PCB boards 21. Connecting screws 212 are inserted into the mounting holes 211 to fix adjacent PCB boards 21. The connecting screws 212 are inserted into the mounting holes 211 to fix the stacked PCB boards 21, reducing the possibility of misalignment of the winding coils 22 between adjacent PCB boards 21. The PCB board 21 has a connecting hole 213 along the axial direction. The inner diameter of the connecting hole 213 is larger than the outer diameter of the rotating shaft 3, so as to prevent the rotating shaft 3 from colliding with the PCB board 21 during rotation and affecting the PCB board 21.

[0032] Reference Figure 1The circumferential sidewall of the PCB board 21 is fitted to the inner sidewall of the volute 1. The inner sidewall of the volute 1 is integrally formed with a limiting step 11 that abuts against the PCB board 21. The inner diameter of the end cover 12 at the step position is smaller than the inner diameter of the volute 1. The side of the end cover 12 facing the volute 1 abuts against the PCB board 21, fixing the PCB stator 2 composed of the stacked PCB boards 21, and preventing the PCB stator 2 from changing position and colliding with the rotor 4 in the volute 1 as much as possible. The outer diameter of the PCB board 21 matches the inner diameter of the volute 1, so as to avoid the PCB board 21 from rotating in the volute 1 as much as possible.

[0033] Reference Figure 2 The PCB board 21 has connection holes 23 at the beginning and end of the winding coils 22. The multi-layer winding coils 22 in the PCB board 21 are connected in parallel to each other through the connection holes 23. Adjacent PCB boards 21 are soldered in parallel through three-phase solder pad holes 25. The multi-layer winding coils 22 on the surface of the PCB board 21 are distributed in a three-phase symmetrical manner. In this embodiment, there are a suitable number of nine groups of winding coils 22 on the PCB board 21. The multi-layer PCB boards 21 are stacked together in parallel to form a three-phase symmetrical winding structure. When appropriate current is applied to the three-phase windings, according to the Faraday electromagnetic induction principle, the magnetic fields generated by the stator and rotor 4 magnetic poles cut each other, generating torque on the rotor 4 and thus driving the rotating shaft 3 to rotate. The PCB board 21 is provided with a bridging line 24 that communicates with the connection holes 23. The bridging line 24 connects the three-phase distributed winding coils 22 in parallel, which can connect the stacked PCB board 21 winding coils 22 in parallel more quickly. The winding coils 22 are bridging and Y-connected on the PCB board 21.

[0034] The implementation principle of this application embodiment is as follows:

[0035] In actual operation, multiple layers of winding coils 22 with a three-phase symmetrical distribution are printed on the PCB board 21. By stacking and welding the multiple layers of PCB board 21 in a single direction, a PCB stator 2 is formed, creating a three-phase symmetrical winding structure, which replaces the stator assembly formed by winding on the stator core. The magnetic field generated by the magnetic poles of the magnetic plates 41 arranged on the N and S pole faces of the rotor 4 on both sides cuts each other, generating torque on the rotor 4, causing the rotating shaft 3 to rotate and drive the impeller 51 to rotate, drawing air from the air inlet 53 of the fan shroud 5, and blowing the air out from the air outlet 52 of the fan shroud 5. The PCB stator 2 does not have a core or a complex winding manufacturing process, resulting in high manufacturing efficiency, extremely high yield of finished products, stable motor parameters, and good consistency.

[0036] The embodiments described in this specific implementation are preferred embodiments of this application and are not intended to limit the scope of protection of this application. Identical components are represented by the same reference numerals. Therefore, all equivalent changes made to the structure, shape, and principle of this application should be covered within the scope of protection of this application.

Claims

1. An axial flux dual rotor PCB motor for a robotic vacuum cleaner, characterized by: The device includes a volute (1) and a PCB stator (2) fixed in the volute (1). One end of the volute (1) is provided with an end cap (12) that cooperates with the volute (1). A rotating shaft (3) is provided between the volute (1) and the end cap (12) and rotatably through the PCB stator (2) along the axial direction. The PCB stator (2) includes several PCB boards (21) stacked and welded in parallel along a single direction. Several winding coils (22) are provided on the PCB boards (21) along the circumferential direction. Rotors (4) are fixedly connected to the two ends of the rotating shaft (3) away from the PCB boards (21). Several magnetic sheets (41) are provided on the end of the rotor (4) facing the PCB stator (2). A fan shroud (5) is provided opposite to the volute (1). A moving impeller (51) fixedly connected to the rotating shaft (3) is rotatably provided in the fan shroud (5).

2. The axial flux double rotor PCB motor for a robotic vacuum cleaner according to claim 1, characterized in that: The edge of the PCB board (21) is provided with a plurality of mounting holes (211) that communicate with the stacked PCB boards (21). The mounting holes (211) are provided with connecting screws (212) for fixing adjacent PCB boards (21).

3. The axial flux double rotor PCB motor for a robotic vacuum cleaner according to claim 2, characterized in that: The PCB board (21) has a connecting hole (213) along the axial direction, and the inner diameter of the connecting hole (213) is larger than the outer diameter of the rotating shaft (3).

4. The axial flux double rotor PCB motor for a robotic vacuum cleaner according to claim 3, characterized in that: The inner wall of the volute (1) is provided with a limiting step (11) that abuts against the PCB board (21). The inner diameter of the end cap (12) at the step position is smaller than the inner diameter of the volute (1). The side of the end cap (12) facing the volute (1) abuts against the PCB board (21).

5. The axial flux double rotor PCB motor for a robotic vacuum cleaner according to claim 4, characterized in that: The outer diameter of the PCB board (21) matches the inner diameter of the volute (1).

6. The axial flux double rotor PCB motor for a robotic vacuum cleaner according to claim 5, characterized in that: The PCB board (21) has connection holes (23) at the beginning and end of the winding coil (22), and the multi-layer winding coils (22) in the PCB board (21) are connected in parallel to each other through the connection holes (23).

7. The axial flux double rotor PCB motor for a robotic vacuum cleaner according to claim 6, characterized in that: The winding coils (22) located on the surface of the PCB board (21) are distributed in a three-phase symmetrical manner.

8. The axial flux double rotor PCB motor for a robotic vacuum cleaner according to claim 7, characterized in that: The PCB board (21) is provided with a jumper line (24) that communicates with the connection hole (23), and the jumper line (24) connects the three-phase distributed winding coils (22).

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