Motor unit and sliding top unit

Abstract

This utility model relates to a motor unit for an electric motor, particularly a brushless motor, and a sliding top unit. The motor unit has a stator unit (1) comprising a plurality of stator windings (20) and a circumferential base structure (10) for accommodating the plurality of stator windings (20), wherein the relative circumferential surfaces (24) of adjacent stator windings (20) are formed to be parallel to each other.

Description

Technical Field

[0001] This utility model relates to a motor unit, particularly a brushless motor unit for a sliding top unit, and also to a sliding top unit comprising such a motor unit. Background Technology

[0002] In motor vehicles, DC motors (DC motors) with brushes and commutators are commonly used as actuators for sunroofs or sliding roofs. Furthermore, existing motors with an outer diameter of up to 40 mm and a rotational speed of approximately 6900 to 10000 rpm are sufficient to drive sliding roofs.

[0003] Using brushes and commutators can generate unpleasant background noise in the high-frequency range (e.g., 3-5 kHz). The rotor's (permanent) magnets are typically arranged at an angle to reduce or optimize the motor's cogging torque, thereby reducing noise.

[0004] However, there are strict requirements for using this type of motor to avoid causing such unpleasant operating noise to vehicle occupants.

[0005] Furthermore, DC motors require more installation space to meet the necessary performance requirements. The use of brushes limits the motor's lifespan; such motors or brushes typically operate for approximately 150 operating hours. On the other hand, in the field of motor vehicles, a longer total operating time is needed to properly address the vehicle's lifespan issue. Utility Model Content

[0006] This invention is based on the purpose of specifying a motor unit that provides optimized handling with improved operating and operational characteristics, allows for simplified manufacturing and can be produced at low cost, and therefore should particularly be able to optimize energy efficiency and noise generation. Furthermore, the aim of this design is to provide a sliding top unit that includes such a motor unit.

[0007] According to this utility model, this objective is solved by the subject matter of this application.

[0008] According to this invention, the motor unit, particularly the brushless motor unit, has a stator unit and a rotor unit for sliding the top unit. The stator unit has a surrounding base structure and multiple stator teeth for accommodating multiple stator windings, thereby forming six slot segments between the stator teeth. Furthermore, the rotor unit has eight magnetic poles.

[0009] This invention is based on the idea that motor units with specific ratios of slots and magnetic poles can reduce noise generation and further optimize the magnetic flux / density along the stator unit, especially within the base structure, to provide improved operating characteristics and optimized service life.

[0010] In particular, the stator unit according to this invention is provided for a brushless motor or a DC motor having a rotor unit arranged in the center such that the stator unit surrounds the rotor unit in its circumference.

[0011] In particular, it can extend the motor's operating time. Furthermore, operating noise can remain at a low level throughout the entire lifespan of the motor unit because there is no wear and tear, such as that on brushes or the like.

[0012] For the purposes of this invention, the surrounding base structure should be understood in particular as a stator unit surrounding a corresponding rotor unit, so that the rotor unit is centrally arranged within the stator unit. In this sense, the base structure of the stator unit can be decomposed into a frame or similar structure. The base structure can form one or more components. In this way, the surrounding characteristic of the base structure can also be provided by multiple assembled parts or parts that are specifically positioned relative to each other.

[0013] The base structure of the stator unit can also be formed or covered with an additional insulating layer.

[0014] The specific shape and arrangement of the stator windings or magnetic coils, especially in combination with the bonded (permanent) magnets of the corresponding or related rotor units, also produce a favorable uniform and sinusoidal cogging torque.

[0015] For the purposes of this invention, multiple stator windings can be specifically understood as multiple stator coils, each stator coil may have multiple (individual) windings to form an electromagnetic coil.

[0016] A specific ratio of 8 magnetic poles and 6 slots or 6 stator teeth with stator windings can advantageously reduce noise generation and optimize cogging torque, with the stator teeth separated from each other by slots.

[0017] In particular, a specific ratio of 8 magnetic poles and 6 slots or 6 stator teeth with stator windings can be used to increase the overall magnetic flux density of the motor, with the stator teeth separated from each other by the slots.

[0018] It can also minimize the number of individual windings in each stator winding or electromagnetic coil, thereby reducing the total copper weight and the resulting material costs.

[0019] According to a preferred embodiment, the rotor unit has multiple magnets, particularly four permanent magnets, to form magnetic poles, and the magnets are preferably formed as bonded magnets.

[0020] In particular, due to the bonded design of the rotor unit's magnets, the balance of the resulting motor unit can be set relatively precisely. Preferably, a tolerance of 50 μm, especially less than 50 μm, can be maintained.

[0021] This prevents the rotor from becoming unbalanced and optimizes the motor's balance. The motor runs more smoothly and produces less noise during operation.

[0022] In addition, damage to the magnets, such as cracking or breaking, can be prevented by bonding design and the overall size of each magnet.

[0023] In addition, the bonding design of the rotor magnets can reduce the weight of the motor.

[0024] The adhesive design of the rotor unit can also reduce manufacturing costs, especially compared to so-called surface permanent magnet motors (SPMs), which use adhesives to attach permanent magnets (separately) to the rotor.

[0025] According to one embodiment, each stator tooth has a central axis, and the corresponding stator winding is symmetrical with respect to the central axis. Each stator tooth may have at least one tooth connection, at least one top surface, and at least one bottom surface.

[0026] According to this invention, each stator winding is symmetrical with respect to its own central axis.

[0027] In this way, uniform or consistent operating characteristics of the resulting motor can be achieved, especially uniform or single-form sinusoidal cogging torque.

[0028] Starting from the surrounding base structure, the stator teeth extend in a direction toward the center. Therefore, the head of each tooth is formed or arranged at the central end of the stator tooth.

[0029] In particular, the geometry of each stator winding is designed such that the mounting space along each stator tooth and the corresponding tooth head is optimally utilized, preferably for arranging the maximum number and / or density of individual windings.

[0030] In this sense, each stator tooth can have a T-shaped base. Therefore, it is possible to provide and ensure targeted and efficient shaping and guidance of the magnetic flux lines generated by the stator windings.

[0031] In a preferred embodiment, the corresponding bottom surface of each stator tooth includes an obtuse angle α relative to the central axis of the respective stator tooth, preferably between 90° and 160°, 110° and 150°, or 120° and 140°, particularly 127°. Furthermore, the radius of the edge guide between the corresponding bottom surface and the corresponding top surface can preferably be between 0.05 and 1.0 mm, 0.1 and 0.5 mm, 0.15 and 0.3 mm, or 0.2 mm.

[0032] In particular, the bottom surface is the side of the stator tooth or tooth head facing the stator winding. The top surface represents the side of the stator tooth or tooth head facing the center or internal area of ​​the motor unit.

[0033] The edge guide between the bottom and top surfaces of the stator teeth can be a rounded edge formed along one end of the top and / or bottom surfaces. Therefore, the top and bottom surfaces do not necessarily need to be adjacent to each other along the edge extension dimension. Instead, an additional side surface can be formed between the top and bottom surfaces, which is adjacent to the top and bottom surfaces along the edge extension dimension.

[0034] By using a specific obtuse angle, particularly 127°, and / or an edge guide with a radius of 0.2 mm extending along the edge of the outer end of the stator teeth, a favorable distribution and guidance of the magnetic flux lines can be provided.

[0035] According to another preferred embodiment, the circumferential surface of each coil winding includes an acute angle β relative to the central axis of the corresponding stator tooth, preferably between 5° and 70°, 10° and 45°, or 20° and 40°, particularly 30°.

[0036] The circumferential or side surface of each stator winding represents the outer or side surface of a preferred (rotational) symmetrical stator winding or coil winding, each winding having multiple conductors or individual windings.

[0037] In particular, the inclined design of the circumferential surfaces allows for the formation or continuation of slots between stator teeth between the circumferential surfaces. This enables advantageous guidance and design of the magnetic flux lines.

[0038] According to one embodiment, the minimum width of the groove segment is between 1 mm and 10 mm, between 2 mm and 5 mm, or between 2.5 mm and 3 mm, particularly 3 mm. Furthermore, according to another embodiment, the tooth width or tooth diameter of each toothed connection is preferably between 0.5 mm and 10 mm, more preferably between 1 mm and 5 mm, between 1.5 mm and 3.5 mm, or between 1.8 mm and 2.5 mm, particularly 2.5 mm.

[0039] With a preferred width of 3 mm for the slot segment between adjacent stator teeth or tooth heads and the coil / stator winding or electromagnetic coil, optimized overall magnetic flux density and optimized cogging torque can be achieved.

[0040] Furthermore, the slot segment, comprising the distance between the circumferential surfaces of the individual stator windings, allows the stator windings in the base structure to be directly wound onto the stator teeth, preferably using tools engaged in the slot segment. This simplifies the manufacturing of the motor unit.

[0041] In addition, the tooth width or tooth diameter is preferably 2.5 mm, which can further optimize the total magnetic flux density or magnetic flux density on each stator winding or electromagnetic coil.

[0042] In particular, a uniform or consistent space can be formed between the stator windings arranged adjacent to each other. In this way, improved operational and manufacturability of the final motor unit can be ensured.

[0043] By optimizing the efficiency of individual stator windings and stator windings as a whole, the number of individual windings required for the corresponding stator windings or electromagnetic coils can be reduced. To achieve specific power values, especially specific magnetic flux densities, reducing the number of individual windings can save copper, thereby enabling cost and space optimization of the stator unit design.

[0044] In one embodiment, the base structure of the stator unit has a hexagonal shape, particularly an outer hexagonal shape. Furthermore, according to one embodiment, the stator unit, particularly the base structure of the stator unit, may be configured to have an outer width of 33.8 mm.

[0045] Stator teeth are preferably formed along the longitudinal sides of the hexagonal base structure, particularly in the middle of each longitudinal side.

[0046] This means that the number of stator windings or electromagnetic coils preferably corresponds to the hexagonal base structure.

[0047] Because the stator teeth are equidistant, meaning they are equidistant from each other, a constant force can be applied to the associated rotor unit along the entire circumference of the stator unit.

[0048] The base structure of the stator unit preferably has a hexagonal extension shape or geometry, and its outer width, in the context of this invention, is determined by the distance between opposite longitudinal segments.

[0049] Compared to the rounded design of the stator unit or the rounded base, the hexagonal geometry offers an advantage in achieving space-saving design. Furthermore, this approach allows for higher motor power density.

[0050] According to another preferred embodiment, the cross-sectional edges of the relative circumferential surfaces of adjacent stator windings or stator coils, particularly the circumferential or side surfaces of adjacent stator windings, are formed parallel to each other.

[0051] In particular, the edges of the circumferential or side surfaces of the stator winding can be aligned parallel to each other, and the circumferential or side surfaces of the stator winding are opposite to each other in the cross-section of the stator winding.

[0052] This parallel configuration of the stator windings relative to each other creates a uniform or consistent space between the individual stator windings or stator coils.

[0053] According to another embodiment, a head receiving portion is arranged at the longitudinal end of the stator unit, the head receiving portion having a plurality of support plates (Haltestegen) and a plurality of support teeth, wherein at least one cable of the motor unit, particularly at least one cable for electrical connection of the stator winding, is guided along the inner side of the support plates and the outer side of the support teeth.

[0054] In this way, a safe and space-saving cable guide can be provided at one end of the stator unit to ensure power supply, especially for the coil windings.

[0055] According to a second aspect of the present invention, a sliding top unit for a vehicle, particularly a motor vehicle, is provided, comprising a motor unit according to the present invention.

[0056] This approach ensures reduced noise during sunroof operation, significantly improving passenger comfort. It also provides optimized cogging torque, improved running time, and enhanced energy efficiency. Attached Figure Description

[0057] The present invention will be explained in more detail below with reference to the embodiments and the schematic diagrams thereof.

[0058] in:

[0059] Figure 1 A cross-sectional view of an embodiment of a motor unit having a rotor unit and a stator unit is shown;

[0060] Figure 2 It shows according to Figure 1 A portion of a cross-sectional view of an embodiment of the motor unit; and

[0061] Figure 3 A perspective view of a portion of the motor unit is shown. Detailed Implementation

[0062] Figure 1 and Figure 2 A cross-sectional view of an embodiment of a motor unit 100 is shown, which includes a stator unit 1 and a rotor unit 2. In particular, the motor unit 100 is designed as a brushless motor.

[0063] The rotor unit 2 is centrally located within the stator unit 1 that surrounds or encircles it.

[0064] The rotor unit 2 shown schematically preferably has a plurality of bonded (permanent) magnets, preferably four magnets, for a total of eight magnetic poles.

[0065] For example, magnets can be bonded or embedded in polymers, i.e., bonded designs.

[0066] Depending on the number of (permanent) magnets, their individual sizes, and the bonding design, the magnets can be protected from damage such as breakage or cracking.

[0067] Furthermore, the rotor unit can be manufactured in a simple, cost-effective manner with only very small tolerances. Additionally, it can improve the operating characteristics of the resulting motor.

[0068] Stator unit 1 is shown as a surrounding stator unit 1.

[0069] according to Figure 1 The stator unit 1 has a surrounding base structure 10. The base structure 10 can be formed as a single component, or alternatively as multiple components.

[0070] In particular, the base structure 10 of stator unit 1, such as Figure 1 and Figure 2 As shown, there is no additional insulating layer. The geometry and dimensions of the base structure, particularly the geometry and dimensions of the stator teeth 12 and slot segments 16, are especially related to the conductive elements of the stator unit.

[0071] Therefore, as Figure 1 and Figure 2 The stator unit 1 shown can also be formed with an additional insulating layer.

[0072] Specifically, the base structure 10 of the stator unit 1 has a hexagonal (basic) shape and geometry. The width of the stator unit 1 (from one of the longitudinal sides to the opposite longitudinal side) can preferably reach 33.8 mm.

[0073] In addition, according to Figure 1 and Figure 2 A total of six stator teeth 12 are provided, which are equidistantly distributed and centered along one of the longitudinal sides of the hexagonal base structure 10, extending in a direction toward the center.

[0074] The slot segment 16 is formed between the stator teeth 12 arranged adjacent to each other.

[0075] The width of the groove is preferably between 2.5 and 3.0 mm, especially 3.0 mm.

[0076] Therefore, the motor unit has a specific ratio of 6 slots in the stator unit 1 to 8 magnetic poles in the rotor unit 2.

[0077] Preferably, the cogging torque and noise generated during the operation of the motor unit can be optimized or reduced, especially for the sliding top unit.

[0078] Tooth heads 30 can be formed at the center end of each stator tooth 12. Thus, the stator teeth 12 and tooth heads 30 extend into the inner region 14 of the base structure 10.

[0079] Furthermore, the longitudinal axis X is formed by each individual stator tooth 12. Preferably, the stator teeth 12 may be formed symmetrically with respect to the corresponding longitudinal axis X.

[0080] In addition, the stator teeth 12 preferably each have a tooth connection portion 36 with a width or diameter of 2.5 mm.

[0081] The toothed connection 36 preferably allows for optimal extension and guidance of the magnetic flux lines.

[0082] The tooth head 30 has a top surface 32 with a circular cross-section facing the rotor unit 2. In contrast to the top surface 32, the tooth head 30 or stator tooth 12 has a bottom surface 34.

[0083] In addition, stator windings or coil windings or electromagnetic coils 20 are formed along each stator tooth 12, particularly along the tooth connection portion 36 facing the bottom surface 34.

[0084] Preferably, the stator windings 12 are symmetrical, particularly rotationally symmetrical, with respect to the longitudinal axis X of the corresponding stator teeth 12. Therefore, all stator windings 20 surround the corresponding stator teeth 12, particularly the corresponding tooth connections 36.

[0085] Furthermore, the bottom surface 34 of the stator teeth forms an obtuse angle α relative to the relevant longitudinal axis X.

[0086] The obtuse angle α is preferably 127°.

[0087] Furthermore, each stator winding 20 has a circumferential surface 24. The circumferential surface 24 forms an acute angle β with the associated longitudinal axis X, preferably an angle of 30°.

[0088] This particular geometry of the stator teeth 12, including the intermediate slot segment 16 and / or stator winding 20, can be specifically used to provide improved operating / operational characteristics of the resulting motor unit.

[0089] Furthermore, it is proposed that the relative circumferential surfaces 24 of the stator windings 20 arranged adjacent to each other are formed or arranged parallel to each other. Therefore, the corresponding slot segments 16 continue to extend between the stator windings or coil windings or electromagnetic coils 20 arranged adjacent to each other, and between the stator teeth 12.

[0090] Figure 3 A perspective view of a portion of the motor unit 100 is shown.

[0091] In particular, the longitudinal end of the stator unit 1 in an embodiment of the motor unit 100 is shown.

[0092] The head receiving section 50 is arranged at the longitudinal end of the stator unit 1.

[0093] The head receiving part 50 generally has a hexagonal (outer hexagonal) shape of the base structure 10 of the stator unit 1.

[0094] Multiple support plates 52 and support teeth 54 are formed, particularly alternately, along the head receiving portion 50.

[0095] according to Figure 3 The support teeth 54 are formed at the corners of the hexagonal base shape of the head receiving part 50.

[0096] In addition, the support plate 52 and the support tooth 54 are spaced apart so that at least one cable 40 of the motor unit 100 can pass through.

[0097] Therefore, at least one cable 40 can be guided or arranged on the outside of the support tooth 54 and can be arranged along the inside of the support plate 52.

[0098] In this way, at least one cable 40 of the motor unit 100 can be fastened and / or at least partially clamped, particularly by means of the support teeth 54.

[0099] In addition, the guide along the interior of the support panel 52 allows for space-saving and safe routing of at least one cable 40.

[0100] In summary, this invention can be used to provide a motor unit 100 that, through the stator and rotor units described herein, particularly an embodiment having six slot segments 16 and eight magnetic poles, ensures improved operating performance, extended service life, and reduced operating noise.

[0101] Furthermore, by combining the specific geometry of the stator teeth 12 with the specific design of the coil windings / stator windings 20 and / or the bonding design of the (permanent) magnets in the rotor unit 2, it is possible to achieve an increased total magnetic flux density and optimized or reduced cogging torque with constant or uniform sinusoidal characteristics.

[0102] By reducing the number of individual windings of the stator windings or electromagnetic coils 20, manufacturing costs, as well as the size and weight of the stator unit 1, can be advantageously reduced.

[0103] Furthermore, the hexagonal (foundation) shape of the base structure 10 can also advantageously reduce the installation space required for the resulting (brushless) motor unit 100.

[0104] List of reference numerals

[0105] 1. Stator Unit

[0106] 2 Rotor Unit

[0107] 10. Base Structure

[0108] 12 stator teeth

[0109] 14 Internal Area

[0110] 16-slot section

[0111] 20 stator windings

[0112] 24 circumferential surfaces

[0113] 30-tooth head

[0114] 32 Top surface

[0115] 34 Bottom surface

[0116] 36-tooth connection

[0117] 40 cable

[0118] 50 Head receiver

[0119] 52 Support plate

[0120] 54 Support teeth

[0121] 100 motor units

[0122] α obtuse angle

[0123] β acute angle

[0124] X-axis

Claims

1. A motor unit (100) for a sliding top unit, comprising a stator unit (1) and a rotor unit (2). in, The stator unit (1) is formed with a surrounding base structure (10) and a plurality of stator teeth (12) for accommodating a plurality of stator windings (20), such that six slot segments (16) are formed between the stator teeth (12). The rotor unit (2) has eight magnetic poles. Each of the stator teeth (12) has at least one tooth connection portion (36), at least one top surface (32) and a bottom surface (34). The respective bottom surface (34) of each stator tooth forms an obtuse angle (α) with respect to the central axis (X) of the respective stator tooth (12), the obtuse angle (α) being between 90° and 160°, and / or The radius of the edge guide extending between the corresponding bottom surface and the corresponding top surface is between 0.05 and 1.0 mm.

2. The motor unit (100) according to claim 1, characterized in that, The rotor unit (2) has four permanent magnets to form the magnetic poles, and the permanent magnets are designed as bonded magnets.

3. The motor unit (100) according to claim 1, characterized in that, Each of the stator teeth (12) has a central axis (X), and the corresponding stator winding (20) is designed symmetrically with respect to the central axis (X).

4. The motor unit (100) according to claim 1, characterized in that, The obtuse angle (α) is 127°, and / or The radius of the edge guide is 0.2 mm.

5. The motor unit (100) according to claim 1, characterized in that, The circumferential surface (24) of each stator winding (20) forms an acute angle (β) with respect to the central axis (X) of the corresponding stator tooth (12).

6. The motor unit (100) according to claim 1, characterized in that, The minimum width of the groove (16) is between 1 mm and 10 mm.

7. The motor unit (100) according to claim 6, characterized in that, The minimum width of the groove segment (16) is 3 mm.

8. The motor unit (100) according to claim 1, characterized in that, The tooth width or tooth diameter of each of the toothed connectors (36) is between 0.5 mm and 10 mm.

9. The motor unit (100) according to claim 1, characterized in that, The base structure (10) of the stator unit (1) has a hexagonal shape.

10. The motor unit (100) according to claim 1, characterized in that, The external width of the stator unit (1) is 33.8 mm.

11. The motor unit (100) according to claim 1, characterized in that, The relative circumferential surfaces (24) of adjacent stator windings (20) are formed to be parallel to each other.

12. The motor unit (100) according to claim 1, characterized in that, The stator unit (1) has a head receiving part (50) arranged at its longitudinal end. The head receiving part (50) has multiple support plates (52) and multiple support teeth (54). At least one cable (40) of the motor unit (100) is guided along the inside of the support plate (52) and along the outside of the support tooth (54).

13. A sliding top unit for a vehicle, comprising a motor unit (100) according to any one of claims 1-12.

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