Motor and actuator using the same
By optimizing the design of the stator windings and permanent magnets, and combining them with a high-ratio gearbox, the problems of large size and low energy density of BLDC motors have been solved, achieving a compact and efficient design of the motor and actuator, and improving energy density and torque output.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- AML AUTOMOTIVE ACTIVE MODULES (WUXI) CO LTD
- Filing Date
- 2025-04-25
- Publication Date
- 2026-06-05
AI Technical Summary
The existing BLDC motors in automotive active grille louver actuators are large in size and have low energy density. It is necessary to reduce the size of the motor to increase the energy density.
By optimizing the number of stator winding turns and the outer diameter of the winding, using high remanence permanent magnets, reducing the number and thickness of stator magnetic chips, and designing a high transmission ratio gearbox, combined with the use of a brushless DC motor and a gearbox, a compact design of the motor and actuator is achieved.
While maintaining essentially the same motor performance, the size of the motor and actuator has been significantly reduced, energy density has been increased, and magnetic field strength and torque output have been enhanced.
Smart Images
Figure CN224329320U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to an electric motor and an actuator using the electric motor, which is particularly suitable as an actuator for an active grille shutter (AGS) in automobiles. Background Technology
[0002] The active grille louver actuator in a car consists of a motor and a gearbox. This motor is typically a brushless direct current (BLDC) motor, which has a relatively low energy density. Therefore, the motor size is usually large to meet the required output torque. Thus, there is a pressing need for an improvement to reduce the motor size. Utility Model Content
[0003] One objective of this application is to reduce the size of the motor and increase its energy density.
[0004] Therefore, one aspect of this application provides an electric motor, including a stator and a rotor rotatably mounted to the stator, wherein: the stator includes a stator core and stator windings wound on the stator core; each stator winding has not less than 400 and not more than 800 turns, and the outer diameter of the winding wire wound on the stator winding does not exceed 0.13 mm; the rotor includes a shaft, a first gear fixedly sleeved on the shaft, and a permanent magnet fixed to the first gear; the permanent magnet is a permanent magnet with a remanence of not less than 600 HOTOs.
[0005] The motor may exhibit one or more of the following features, either individually or in combination.
[0006] In one embodiment of this utility model, the number of turns of each stator winding is not less than 500 and not more than 700, and the outer diameter of the winding wire used to wind the stator winding does not exceed 0.12 mm; the permanent magnet is a permanent magnet with a remanence of not less than 700 watts.
[0007] In one embodiment of the present invention, the stator core includes an outer frame, the outer frame including a plurality of arc-shaped portions and a plurality of outwardly protruding portions, the arc-shaped portions and outwardly protruding portions being alternately arranged and connected to form the outer frame; the stator core also includes stator teeth extending inward from the outwardly protruding portions, the stator windings being disposed on the corresponding stator teeth; the rotor is housed in the space formed by the inner ends of the arc-shaped portions and the stator teeth.
[0008] In one embodiment of this utility model, the stator core is formed by stacking a plurality of magnetic chips, the number of magnetic chips not exceeding 16, and the height of the stator core not exceeding 8 mm.
[0009] In one embodiment of this utility model, the number of magnetic chips does not exceed 12, and the height of the stator core does not exceed 6 mm.
[0010] In one embodiment of the present invention, the first gear includes an integrally formed gear body and a connecting part, the connecting part being connected to one end of the gear body, and the permanent magnet being fixedly installed to the connecting part.
[0011] In one embodiment of this utility model, the motor is a brushless DC motor, including a circuit board assembly, the circuit board assembly including a circuit board; the stator and rotor are located on one side of the circuit board, and the rotating shaft is substantially perpendicular to the circuit board.
[0012] Another objective of this application is to reduce the size of the actuator and increase its energy density.
[0013] Therefore, in a second aspect of this application, an actuator is provided, including a gearbox and a motor provided in the first aspect of this application, wherein the gearbox is connected to the motor for reducing the output of the motor.
[0014] The actuator may present one or more of the following features individually or in combination.
[0015] In one embodiment of this utility model, the gearbox has a transmission ratio of not less than 500; the motor is housed within the gearbox housing.
[0016] In one embodiment of the present invention, the gearbox includes a housing and an output wheel, the output wheel including a gear shaft; the housing has a through hole for the gear shaft to pass through, the wall of the through hole supports the gear shaft, and the wall of the through hole has a receiving cavity at a position away from the outer surface of the housing; the gearbox further includes a dynamic sealing ring housed in the receiving cavity, the dynamic sealing ring being used to seal the outer periphery of the gear shaft and the wall of the receiving cavity.
[0017] In one embodiment of the present invention, the dynamic sealing ring includes an outer ring portion and an inner ring portion. The outer ring portion extends axially along the gear shaft, and the inner ring portion extends inward from the outer ring portion and toward the outer surface of the housing. The radially inner end of the inner ring portion contacts the gear shaft.
[0018] Implementing this utility model can improve the energy density of the motor, and reduce the size of the motor and the corresponding actuator while maintaining basically the same motor performance. Attached Figure Description
[0019] To further reveal the specific technical content of this case, please first refer to the accompanying drawings, in which:
[0020] Figure 1 This is a schematic diagram of an actuator provided in one embodiment of the present invention;
[0021] Figure 2 yes Figure 1 An exploded view of the actuator shown.
[0022] Figure 3 yes Figure 1 A planar schematic diagram of the actuator shown;
[0023] Figure 4 yes Figure 3 A schematic diagram of the AA cross-section of the actuator shown;
[0024] Figure 5 yes Figure 4 An enlarged view of part B of the actuator shown;
[0025] Figure 6 and Figure 7 yes Figure 2 Schematic diagrams of the motor used by the actuator from different viewing angles;
[0026] Figure 8 yes Figure 7 A schematic diagram of the stator core used in the motor shown;
[0027] Figure 9 yes Figure 7 A schematic diagram of the rotor used in the motor shown;
[0028] Figure 10 yes Figure 9 The diagram shows a longitudinal section of the rotor. Detailed Implementation
[0029] The technical solutions in the embodiments of this utility model will now be described with reference to the accompanying drawings.
[0030] refer to Figure 1 and Figure 2 An actuator 100 provided in one embodiment of this utility model includes a motor 10 and a gearbox 60. The motor 10 includes a stator 20 and a rotor 40 rotatable relative to the stator 20. The gearbox 60 is connected to the motor 10 and reduces the output of the motor 10. The gear ratio of the gearbox 60 is not less than 500, so that the output gear 80 of the last stage of the gearbox 60 has a larger output torque. In this application, the gear ratio of the gearbox 60 refers to the ratio of the rotational speed of the first stage gear to the rotational speed of the last stage gear. Preferably, the gear ratio of the gearbox 60 is not less than 550. In this embodiment, the motor 10 is also relatively small and can be housed within the housing 61 of the gearbox 60. The housing 61 is connected to a connector 62 for connection to the outside. Understandably, the motor 10 may also be located outside the housing 61 of the gearbox 60.
[0031] In this embodiment, the housing 61 includes a bottom shell 63 and a cover 64. The cover 64 is installed at the open end of the bottom shell 63 and forms a large receiving cavity with the bottom shell 63, which is used to house the motor 10, the gearbox 60, and the various stages of double gears 71, 72, 73, and the output wheel 80. The structures of the various stages of double gears 71, 72, and 73 are basically the same. Each double gear includes a large gear and a small gear fixed coaxially. For example, double gear 73 includes a large gear 73a and a small gear 73b fixed coaxially. Each double gear receives input from the gear of the previous stage through its large gear and outputs to the gear of the next stage through its small gear. For example, the large gear of double gear 71 is fixedly sleeved onto the first gear 42 of the rotor 40's shaft 41 (see...). Figure 6 The large gear of the double gear 72 is driven by the small gear of the double gear 71, which in turn drives the small gear of the double gear 72 to rotate coaxially, thus achieving a reduction in output speed. The large gear 73a of the double gear 73 is driven by the small gear of the double gear 72, which in turn drives the small gear 73b of the double gear 73 to rotate coaxially, thus achieving a reduction in output speed. The gear body 83 of the output wheel 80 meshes with the small gear 73b, receives input from the small gear 73b, and drives the gear shaft 81 to rotate, thereby outputting to the outside. In this embodiment, a non-circular through hole or blind hole 82 is formed in the middle of the gear shaft 81 to facilitate driving external objects, such as driving the grille louvers of a car.
[0032] refer to Figures 2 to 5 The output wheel 80 includes a gear shaft 81 and a gear body 83 fixed to the gear shaft 81. The gear body 83 is housed within a receiving cavity formed by a bottom shell 63 and a cover 64. The bottom shell 63 and the cover 64 are respectively provided with through holes 65 and 75 for the gear shaft 81 of the output wheel 80 to pass through. The hole wall 66 of the through hole 65 and the hole wall 76 of the through hole 75 support the gear shaft 81 so that the output wheel 80 can rotate relative to the shell 61. The hole wall 66 of the through hole 65 has a receiving cavity 67 at a position away from the outer surface of the shell 61 for installing a dynamic sealing ring 90; similarly, the hole wall 76 of the through hole 75 has a receiving cavity 77 at a position away from the outer surface of the shell 61 for installing a dynamic sealing ring 95. After the actuator 100 is assembled, the dynamic sealing rings 90 and 95 are respectively fitted onto both ends of the gear shaft 81 of the output wheel 80 and housed in the receiving cavities 67 and 77, respectively, to seal the outer circumference of the gear shaft 81 and the walls of the receiving cavities 67 and 77. Because the dynamic sealing rings 90 and 95 are located in the receiving cavities 67 and 77, which are recessed relative to the bore walls, they are not easily touched by external objects, thus preventing damage and ensuring the sealing effect of the actuator 100, thereby extending the service life of the dynamic sealing rings 90 and 95 and the actuator 100.
[0033] Preferably, the dynamic sealing rings 90 and 95 have the same shape. The description will take dynamic sealing ring 95 as an example. (See reference...) Figure 5 The dynamic sealing ring 95 includes an outer ring portion 91 and an inner ring portion 92. The outer ring portion 91 extends axially along the gear shaft 81, and the inner ring portion 92 extends inward from the outer ring portion 91 and toward the outer surface of the housing 61. The radially inner end of the inner ring portion 92 contacts the gear shaft 81. Thus, the cross-section of the dynamic sealing ring 95 forms a U-shape, making it difficult for external objects to pass over the dynamic sealing ring 95 and enter the interior of the actuator 100 even if they enter the receiving cavity 91.
[0034] refer to Figures 6 to 10 The actuator 100's motor 10 is a brushless DC motor, including a circuit board assembly 30, which includes a circuit board 31. A stator 20 and a rotor 40 are located on one side of the circuit board 31. The stator 20 is fixedly connected to the housing 61 by screws or threaded rods, and the rotor 40 is rotatably mounted to the stator 20. The stator 20 includes a stator core 21 and stator windings 28 wound around the stator core 21. In this embodiment, each stator winding 28 has a number of turns not less than 400 and not more than 800, and the outer diameter of the winding wire does not exceed 0.13 mm. Compared to conventional stator windings with approximately 250 turns and an outer diameter of 0.16 mm, the stator winding 28 of this invention has a stronger magnetic field strength when energized, without significantly increasing its volume, and may even have a smaller volume. Compared to existing designs, this invention reduces the volume of the stator winding while maintaining the same or even higher magnetic field strength when energized.
[0035] The rotor 40 includes a shaft 41, a first gear 42 fixedly sleeved onto the shaft 41, and a permanent magnet 45 fixedly attached to the first gear 42. The permanent magnet 45 is a permanent magnet with a residual magnetic induction (Br) of not less than 600 millitriles (mT). Compared with existing designs, the rotor 40 is smaller in size through the design of this utility model, and can generate the same or greater torque when the stator 20 is energized. The first gear 42 includes an integrally formed gear body 43 and a connecting part 44, the connecting part 44 being connected to one end of the gear body 43, and the permanent magnet 45 being fixedly mounted to the connecting part 44. Preferably, the first gear 42 is integrally molded from plastic, and the connecting part 44 has a cavity 46 at the end away from the gear body 43 to reduce weight.
[0036] Preferably, the number of turns of each stator winding 28 is not less than 500 and not more than 700, and the outer diameter of the winding wire of the stator winding 28 does not exceed 0.12 mm; the permanent magnet 45 is a permanent magnet with a remanence of not less than 700 watts.
[0037] In this embodiment, the stator core 21 includes an outer frame 22, which includes a plurality of arcuate portions 23 and a plurality of protruding portions 24. The arcuate portions 23 and the protruding portions 24 are alternately arranged and connected to form the outer frame 22. The stator core 21 also includes stator teeth 25 extending inward from the protruding portions 24, and stator windings 28 are disposed on the corresponding stator teeth 25. The rotor 40 is housed in the space formed by the inner ends of the arcuate portions 23 and the stator teeth 25.
[0038] The stator core 21 is formed by stacking a number of magnetic chips, the number of which does not exceed 16 chips, and the height of the stator core 21 does not exceed 8 mm. Preferably, the number of magnetic chips does not exceed 12 chips, and the height of the stator core 21 does not exceed 6 mm.
[0039] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of this patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.
Claims
1. An electric motor comprising a stator (20) and a rotor (40) rotatably mounted to said stator (20), characterized in that: The stator (20) includes a stator core (21) and stator windings (28) wound around the stator core (21); the number of turns of each stator winding (28) is not less than 400 and not more than 800, and the outer diameter of the winding wire used to wind the stator winding (28) does not exceed 0.13 mm; The rotor (40) includes a shaft (41), a first gear (42) fixedly sleeved on the shaft (41), and a permanent magnet (45) fixed to the first gear (42); the permanent magnet (45) is a permanent magnet with a remanence of not less than 600 watts.
2. The motor as described in claim 1, characterized in that, The number of turns of each stator winding (28) is not less than 500 and not more than 700, and the outer diameter of the winding wire used to wind the stator winding (28) is not more than 0.12 mm; the permanent magnet (45) is a permanent magnet with a remanence of not less than 700 HOUT.
3. The motor as described in claim 1, characterized in that, The stator core (21) includes an outer frame (22), which includes a plurality of arc-shaped portions (23) and a plurality of outward protrusions (24). The arc-shaped portions (23) and outward protrusions (24) are alternately arranged and connected to form the outer frame (22). The stator core (21) also includes stator teeth (25) extending inward from the outward protrusions (24). The stator windings (28) are disposed on the corresponding stator teeth (25). The rotor (40) is housed in the space formed by the inner ends of the arc-shaped portions (23) and the stator teeth (25).
4. The motor as described in claim 1, characterized in that, The stator core (21) is formed by stacking a number of magnetic chips, the number of which does not exceed 16, and the height of the stator core (21) does not exceed 8 mm.
5. The motor as described in claim 4, characterized in that, The number of magnetic chips shall not exceed 12, and the height of the stator core (21) shall not exceed 6 mm.
6. The motor as described in claim 1, characterized in that, The motor is a brushless DC motor, including a circuit board assembly (30), which includes a circuit board (31); the stator (20) and rotor (40) are located on one side of the circuit board (31), and the rotating shaft (41) is substantially perpendicular to the circuit board (31).
7. An actuator comprising a gearbox (60), characterized in that, It also includes a motor as described in any one of claims 1 to 6; the gearbox (60) is connected to the motor for reducing the output of the first gear (42) of the motor.
8. The actuator as claimed in claim 7, characterized in that, The gearbox (60) has a transmission ratio of not less than 500; the motor is housed within the housing of the gearbox (60).
9. The actuator as claimed in claim 7, characterized in that, The gearbox (60) includes a housing (61) and an output wheel (80), the output wheel (80) including a gear shaft (81); the housing (61) has a through hole for the gear shaft (81) to pass through, the wall of the through hole supports the gear shaft (81), and the wall of the through hole has a receiving cavity at a position away from the outer surface of the housing (61); the gearbox (60) also includes a dynamic sealing ring housed in the receiving cavity, the dynamic sealing ring being used to seal the outer periphery of the gear shaft (81) and the wall of the receiving cavity.
10. The actuator as claimed in claim 9, characterized in that, The dynamic sealing ring includes an outer ring portion (91) and an inner ring portion (92). The outer ring portion (91) extends axially along the gear shaft (81), and the inner ring portion (92) extends inward from the outer ring portion (91) and toward the outer surface of the housing (61). The radially inner end of the inner ring portion (92) contacts the gear shaft (81).