Brushless motor, manufacturing method therefor and apparatus

Abstract

The present disclosure relates to a brushless motor, a manufacturing method therefor and an apparatus. The brushless motor comprises: at least one stator core (1), each stator core (1) comprising a plurality of tooth groups (11) which are spaced apart in a circumferential direction thereof, and the total number of the tooth groups (11) being Z; a rotor (2), which can rotate relative to the stator core (1), the rotor (2) comprising a magnetic ring (21) having a pole number of P, and P being an even number; and at least two-phase wires (3), which are wound around the tooth groups (11) to form coils (31) on the tooth groups (11), the total number of phases of the wires (3) being X, each phase wire (3) having an independent first end and second end, for the same phase wire, the number of tooth groups (11) spaced between coils (31) on two adjacent tooth groups (11) being X-1, winding directions of the coils (31) on the two adjacent tooth groups (11) in the circumferential direction of the tooth groups (11) being opposite, and Z=P*X.

Description

Brushless motor and manufacturing method and equipment thereof Technical Field

[0001] The present disclosure relates to a brushless motor and a manufacturing method and equipment thereof. Background Art

[0002] Brushless DC motors (BLDCs) offer the advantages of traditional DC motors, but without the carbon brushes and slip rings, enabling low-speed, high-power operation. They are not only compact and lightweight, but also offer excellent stability and high efficiency, making them widely used in various fields.

[0003] While various brushless motors currently offer some basic performance benefits, they still struggle to achieve optimal overall performance. This is primarily due to the difficulty in balancing multiple performance indicators, such as torque and efficiency. When selecting a motor, the most critical performance indicator must be prioritized based on the application. Therefore, the overall performance of brushless motors needs to be further improved to better meet the demands of automated drives.

[0004] Summary of the Invention

[0005] Some embodiments of the present disclosure provide a brushless motor and a manufacturing method and device thereof, which can improve the overall performance of the brushless motor.

[0006] According to a first aspect of the present disclosure, there is provided a brushless motor comprising:

[0007] at least one stator core, the stator core comprising a plurality of tooth groups spaced apart along its circumference, the total number of the tooth groups being Z;

[0008] a rotor rotatable relative to the stator core, the rotor including a magnetic ring having a pole number P, where P is an even number; and

[0009] At least two phase conductors are wound around the tooth groups to form coils on the tooth groups, the total number of phases of the conductors being X, and each phase conductor having an independent first end and a second end; for the same phase conductor, the number of tooth groups between the coils on two adjacent tooth groups is X-1, and the coils on the two adjacent tooth groups are wound in opposite directions along the circumference of the tooth groups;

[0010] Among them, Z=P*X.

[0011] In some embodiments, the tooth group includes a single tooth, and the wire is wound around the tooth to form a coil on the tooth; and / or the tooth group includes at least two teeth, and the at least two teeth are arranged at intervals along the circumference of the stator core, and the wire is wound around the at least two teeth to form a coil on the at least two teeth.

[0012] In some embodiments, each phase conductor is configured to carry an independent drive signal.

[0013] In some embodiments, in the radial direction of the stator core, the winding direction of each coil formed by at least two phase conductors is consistent.

[0014] In some embodiments, a starting winding position of each coil formed by at least two-phase conductors is located on a side away from the rotor.

[0015] In some embodiments, in the radial direction of the stator core, the first end and the second end of at least two phase conductors are led out from the same side of the teeth set.

[0016] In some embodiments, in a circumferential direction of the stator core, all of the first ends and the second ends are led out from a plurality of adjacent tooth groups.

[0017] In some embodiments, the winding directions of the coils of at least two phase conductors located at the same serial number from the first end along the circumference of the tooth group are consistent; or the winding directions of the coils of at least one group of adjacent two phase conductors located at the same serial number from the first end along the circumference of the tooth group are opposite.

[0018] In some embodiments, at least two phase conductors are wound sequentially from phase 1 to phase X along the circumference of the stator core;

[0019] The conductors for inputting the driving signal include the i-th phase conductor and the k-th phase conductor. The phase difference between the driving signal of the i-th phase conductor and the driving signal of the k-th phase conductor is Among them, 1≤i<k≤X;

[0020] In the same stator core, the tooth group of the x-th phase conductor and the adjacent tooth groups on both sides have a gap at the closest position, and the gap has a center position in the circumferential direction of the stator core; in all gaps formed by the Z tooth groups, the central angle corresponding to the arc between the center position of the x-th phase conductor and the adjacent center position in the circumferential direction of the stator core is β X , and β X The corresponding sector includes at least part of the tooth group of the xth phase conductor.

[0021] In some embodiments, multiple stator cores are stacked in the axial direction, and each stator core includes at least one phase conductor. In the circumferential direction of the stator core, the tooth groups of the multiple stator cores are staggered.

[0022] In some embodiments, within the entire target rotational speed range of the rotor, the strength of the driving signals input into the conductors of all phases is consistent.

[0023] In some embodiments,

[0024] When the target torque of the rotor is higher than the first preset torque, the strength of the driving signal passed through each phase conductor is consistent;

[0025] When the target torque of the rotor is not higher than the first preset torque, the drive signals passed into the wires of some phases have a preset strength, and the drive signals passed into the wires of the remaining phases are lower than the preset strength or are not driven.

[0026] In some embodiments, the brushless motor has a first operating mode. In the first operating mode, each phase conductor is energized at all times, and driving signals between adjacent phase conductors have a phase difference.

[0027] In some embodiments, the brushless motor has a second operating mode. In the second operating mode, each phase conductor is intermittently energized, and driving signals between adjacent phase conductors have a phase difference.

[0028] In some embodiments, the magnetic ring is sleeved outside the stator core.

[0029] In some embodiments, the stator core is annular and is sleeved outside the magnetic ring.

[0030] In some embodiments, the stator core and the magnetic ring are axially overlapped, and the magnetic ring at least partially covers the coil in the radial direction of the stator core.

[0031] In some embodiments, magnetic rings are provided on both sides of the stator core along the axial direction; and / or

[0032] Stator cores are provided on both sides of the magnetic ring along the axial direction.

[0033] According to a second aspect of the present disclosure, a device is provided, comprising the brushless motor of the above embodiment.

[0034] According to a third aspect of the present disclosure, a method for manufacturing the brushless motor according to the above embodiment is provided, comprising:

[0035] Wire supply steps: provide a wire;

[0036] Winding steps: Wind the wire on the tooth groups in different phase sequences until a coil is formed on each tooth group; among all coils of the wire in the same corresponding tooth group, the number of tooth groups between the coils on two adjacent tooth groups is X-1, and the winding directions of the coils on two adjacent tooth groups along the circumference of the tooth group are opposite;

[0037] Disconnection step: disconnect the conductors at the connection points of adjacent phase sequences so that the total number of phases of the conductors is X, and each phase conductor has an independent first end and second end.

[0038] Based on the above technical solutions, the present invention has at least the following beneficial effects: (1) The number of phases of the motor is increased, which can achieve greater torque and can be applied to high-power products; (2) The conductors of each phase are independent and can be powered independently, so that each phase conductor can be energized at all times to rotate the rotor, and the utilization rate of the winding and the stator core is improved, thereby increasing the maximum working efficiency; the power supply of each phase conductor does not need to be frequently switched, which can improve the working stability and reduce the working noise. During steady-state driving, the force is evenly distributed and it is not easy to generate jitter inside the stator core, which can improve the working stability and overall life of the motor; (3) The number of magnetic poles of the magnetic ring can be reduced. For the same speed and power, two switching of power is required to complete the rotation of a pair of magnetic poles, which can reduce the driving frequency and reduce the driving difficulty; (4) The conductors of the same phase are wound alternately, the winding method is simple, and the degree of automation of the winding can be improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The drawings described herein are used to provide a further understanding of the present disclosure and constitute a part of this application. The illustrative embodiments of the present disclosure and their descriptions are used to explain the present disclosure and do not constitute an improper limitation of the present disclosure. In the drawings:

[0040] FIG1 is a schematic diagram showing the coordination between the stator core and the magnetic ring in the first embodiment of the brushless motor disclosed herein;

[0041] FIG2 is a schematic diagram of the structure of two-phase conductors wound around the stator core in the first embodiment of the brushless motor disclosed herein;

[0042] FIG3 is a schematic diagram showing the working principle of the two-phase brushless motor disclosed herein;

[0043] FIG4 is a schematic diagram of the coordination between the stator core and the magnetic ring in the second embodiment of the brushless motor disclosed herein;

[0044] FIG5 is a schematic diagram of a structure in which two-phase conductors are wound around a stator core in a second embodiment of the brushless motor disclosed herein;

[0045] FIG6 is a schematic diagram of a brushless motor in the present disclosure in which two-phase conductors are both fed with continuous sinusoidal wave drive signals;

[0046] FIG7 is a schematic diagram of a brushless motor in the present disclosure in which two-phase conductors are both fed with non-continuous sinusoidal wave drive signals;

[0047] FIG8 is a schematic diagram of a brushless motor in the present disclosure in which two-phase conductors are both fed with square wave drive signals;

[0048] FIG9 is a schematic diagram showing the coordination between the stator core and the magnetic ring in the third embodiment of the brushless motor disclosed herein;

[0049] FIG10 is a schematic diagram of the structure of the three-phase wires wound around the stator core in the third embodiment of the brushless motor disclosed herein;

[0050] FIG11 is a schematic diagram showing a three-phase brushless motor in which all the wires are fed with a continuous sinusoidal drive signal;

[0051] FIG12 is a schematic diagram showing a three-phase brushless motor in which a square wave drive signal is applied to all the wires;

[0052] FIG13 is a schematic diagram showing the coordination between the stator core and the magnetic ring in the fourth embodiment of the brushless motor disclosed herein;

[0053] FIG14 is a schematic diagram of a fourth embodiment in which continuous sinusoidal wave drive signals are applied to both phase conductors;

[0054] FIG15 is a schematic diagram of the structure of the fifth embodiment of the brushless motor disclosed herein, in which two-phase conductors are wound around the stator core;

[0055] FIG16 is a schematic structural diagram of a magnetic ring in a fifth embodiment;

[0056] FIG17 is a schematic diagram of the structure of the stator core and the rotor in the fifth embodiment;

[0057] FIG18 is a structural diagram of a modified example of the cooperation between the stator core and the rotor in the fifth embodiment;

[0058] FIG19 is a schematic structural diagram of another modified example of the coordination between the stator core and the rotor in the fifth embodiment;

[0059] FIG20 is a cross-sectional view of a sixth embodiment of the brushless motor disclosed herein;

[0060] FIG21 is a schematic diagram of the structure of an X1 phase conductor wound around one of the stator cores in the sixth embodiment;

[0061] FIG22 is a schematic structural diagram of another stator core wound with an X2 phase conductor in the sixth embodiment;

[0062] FIG23 is a schematic structural diagram of two stator cores superimposed along the axial direction in the sixth embodiment.

[0063] Description of reference numerals:

[0064] 1. stator core; 11. tooth group; 11', tooth; 111, neck; 112, shoe; 12, yoke;

[0065] 2. Rotor; 21. Magnetic ring; 22. Rotating shaft;

[0066] 3. Wire; 31. Coil; 32. Connecting section;

[0067] 4. Connecting shaft. DETAILED DESCRIPTION

[0068] Various exemplary embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings. The description of the exemplary embodiments is merely illustrative and is in no way intended to limit the present disclosure, its application, or use. The present disclosure can be implemented in many different forms and is not limited to the embodiments described herein. These embodiments are provided to make the present disclosure thorough and complete and to fully convey the scope of the present disclosure to those skilled in the art. It should be noted that unless otherwise specifically stated, the relative arrangement of parts and steps, the composition of materials, numerical expressions, and numerical values ​​set forth in these embodiments should be interpreted as being merely exemplary and not as limiting.

[0069] The terms "first", "second" and similar terms used in this disclosure do not indicate any order, quantity or importance, but are only used to distinguish different parts. The terms "include" or "comprises" and similar terms mean that the elements before the term include the elements listed after the term, and do not exclude the possibility of also including other elements. The terms "upper", "lower", "left", "right" and the like are only used to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0070] In the present disclosure, when a specific device is described as being located between a first device and a second device, an intervening device may or may not be present between the specific device and the first device or the second device. When a specific device is described as being connected to another device, the specific device may be directly connected to the other device without any intervening device, or may be connected to the other device without any intervening device but with an intervening device.

[0071] All terms (including technical or scientific terms) used in this disclosure have the same meaning as those understood by one of ordinary skill in the art to which this disclosure belongs, unless otherwise specifically defined. It should also be understood that terms defined in, for example, general dictionaries should be interpreted as having a meaning consistent with their meaning in the context of the relevant technology, and should not be interpreted in an idealized or highly formal sense, unless explicitly defined herein.

[0072] Technologies, methods, and equipment known to ordinary technicians in the relevant art may not be discussed in detail, but where appropriate, the technologies, methods, and equipment should be considered part of the specification.

[0073] The present disclosure provides a motor, hereinafter referred to as a "motor," which may be an electric motor for converting electrical energy into mechanical energy, or a generator for converting mechanical energy into electrical energy. In some embodiments, as shown in Figures 1 to 23 , the motor includes:

[0074] At least one stator core 1, the stator core 1 comprising a plurality of tooth groups 11 spaced apart along its circumference, the total number of the tooth groups 11 being Z;

[0075] a rotor 2 rotatable relative to the stator core 1 , the rotor 2 including a magnetic ring 21 having a pole number P, where P is an even number; and

[0076] At least two phase conductors 3 are wound around the teeth 11 to form coils 31 on the teeth 11. The total number of phases of the conductors 3 is X, and each phase conductor 3 has an independent first end and a second end. For the same phase conductor 3, the number of teeth 11 between the coils 31 on two adjacent teeth 11 is X-1, and the coils 31 on the two adjacent teeth 11 are wound in opposite directions along the circumference of the teeth 11.

[0077] Among them, Z=P*X.

[0078] In this embodiment, one or more stator cores 1 may be provided, and each stator core 1 may include a yoke 12 and a plurality of tooth sets 11, with the plurality of tooth sets 11 connected to the yoke 12. For example, the yoke 12 may be annular, such as a circular ring. As shown in FIG1 , the plurality of tooth sets 11 are connected to the outer sidewall of the yoke 12; as shown in FIG4 , the plurality of tooth sets 11 are connected to the inner sidewall of the yoke 12; and as shown in FIG15 , the plurality of tooth sets 11 are connected to the axial ends of the yoke 12.

[0079] The total number of tooth groups 11 is Z. If there are more than two stator cores 1, the total number of tooth groups 11 is the number of tooth groups 11 in all stator cores 1. A tooth group 11 may include one or at least two teeth 11'. A tooth group 11 is formed by grouping all teeth 11' in each stator core 1 according to the winding arrangement, with each group defined as a tooth group 11.

[0080] The rotor 2 can be coaxially arranged with the stator core 1 and rotatable relative to the stator core 1. Referring to Figures 17 to 19 , the rotor 2 can include a magnetic ring 21 and a rotating shaft 22. The rotating shaft 22 is connected to the magnetic ring 21 and is used to output the power of the motor. The number of poles P of the magnetic ring 21 is an even number, P ≥ 2. For example, the number of poles P of the magnetic ring 21 in Figure 1 is 4, i.e., it has two pairs of magnetic poles, which are alternately arranged in a NSNS manner along the circumference of the stator core 1. In addition, the number of poles P can also be 6, 8, etc. Regarding different structural forms, as shown in Figure 1, the magnetic ring 21 is arranged outside the stator core 1; as shown in Figure 4, the stator core 1 is annular, and the magnetic ring 21 is arranged inside the stator core 1; as shown in Figure 16, the magnetic ring 21 and the stator core 1 are arranged axially superimposed.

[0081] At least two phase conductors 3 are wound around tooth groups 11 to form coils 31 on these tooth groups 11. The total number of phases of conductors 3 is X, meaning that after winding, the stator core 1 has X independent conductors 3. Each phase conductor 3 has an independent first and second end. For example, the first end is the input end and the second end is the output end, or vice versa. Each phase conductor 3 forms a coil 31 on a corresponding tooth group 11. The coils 31 on two adjacent tooth groups 11 are connected by a connecting section 32. This connecting section 32 extends from the end surface of the stator core 1 across the tooth groups 11 corresponding to the other phase conductors 3.

[0082] Each phase conductor 3 is represented by X1, X2, ..., respectively. The number of tooth groups 11 between the coils 31 on two adjacent tooth groups 11 is X-1. For example, Figures 1 and 2 show two-phase conductors 3. For each phase conductor 3, winding is performed once for every tooth group 11 that is present. Figures 9 and 10 show three-phase conductors 3. For each phase conductor 3, winding is performed once for every two adjacent tooth groups 11 that are present.

[0083] In terms of parameter selection, the number of poles P of the magnetic ring 21 mainly depends on the design power of the motor. The greater the power, the more poles are required, and the more poles, the greater the torque. The number of poles P is also related to the motor shape. There are also different considerations when determining the magnetic poles of the inner rotor and the outer rotor, but the ultimate goal is to maximize the number and density of windings within a reasonable motor space to achieve the maximum output power of the motor. In addition, increasing the power can also increase the axial thickness of the magnet and stator core 1 or the magnetic force of the magnet material. For the number of phases X, a two-phase motor is generally selected to simplify the structure and reduce the driving difficulty. However, in some applications, the torque can be increased by increasing the number of phases X. For example, on an electric bicycle, it is necessary to increase the torque of the motor within a reasonable size range. Using a three-phase winding can effectively increase the output torque of the motor and also achieve high torque output at low speeds.

[0084] Next, the operating principle of this motor is explained. As shown in Figure 3, for ease of understanding, the magnetic ring 21 and multiple teeth 11' are shown in a linearly expanded form. Taking a two-phase motor as an example, the coils 31 on two adjacent tooth groups 11 are wound in opposite directions along the circumference of the tooth groups 11. Therefore, when the conductors 3 are energized to rotate the rotor 2, if the coil 31 on a tooth 11' of the A-phase conductor 3 generates an N-pole magnetic field, and this tooth 11' is aligned with the critical point O of the magnetic pole S, then the two adjacent teeth 11' are wound around the B-phase conductor 3. These two coils 31, due to their opposite winding directions, generate N and S magnetic fields, respectively. For example, the N-pole magnetic field on the left attracts the magnetic pole S, while the S-pole magnetic field on the right repels the magnetic pole S. The opposing magnetic fields generated by the adjacent phase conductors 3 generate thrust and pull, respectively. This can significantly force the tooth group 11 corresponding to the A-phase conductor 3 past the critical point O, causing the magnetic ring 21 to move in the direction of the arrow.

[0085] The motor of this embodiment has at least one of the following advantages:

[0086] (1) Compared with single-phase motors, single-phase motors are difficult to achieve large torque and are only suitable for low-power products such as handheld fans, computer cooling fans, small table fans, etc. The reason is that they need to rely on the rotational inertia of the rotor to pass through the critical point where the rotor poles and teeth are aligned. However, these products will have obvious electromagnetic noise when used.

[0087] The motor disclosed herein has a larger number of phases. When the tooth group 11 corresponding to a phase conductor 3 reaches the critical point O, the coils 31 on either side of the tooth group 11 in the remaining phase conductors 3, with opposite winding directions, generate magnetic fields in opposite directions. This, in turn, generates thrust and pull forces on the tooth group 11 that has reached the critical point O. This can significantly force the tooth group 11 corresponding to the A-phase conductor past the critical point O. Therefore, this motor can achieve high torque and is suitable for high-power applications.

[0088] (2) Compared with traditional three-phase motors, traditional three-phase motors are driven by cross-powering the UVW three-phase windings. To achieve stable load rotation, the three-phase windings need to be switched on and off according to six regular patterns. During the driving power-on process, there is always one phase of the winding that is not energized and does not do work, so that the maximum utilization rate of the winding and the iron core is only about 66%. The combination and working principle of this three-phase motor result in its low ultimate efficiency, and frequent power switching will bring about greater working noise; moreover, the windings are staggered and intermittently energized, and the law of the reaction force on the iron core when the iron core generates magnetic pull will cause the inside of the iron core to vibrate. When the motor is switched at high speed, it is easy to generate high-frequency vibration, poor working stability, and affect the bearing life.

[0089] The phase conductors 3 in the motor disclosed herein are independent of each other and can be independently powered and driven. Each phase conductor 3 can be energized at all times to rotate the rotor 2, and the utilization rate of the winding and stator core can reach 100%, thereby increasing the maximum working efficiency of the motor. Moreover, the power supply of each phase conductor 3 does not need to be frequently switched, which improves the working stability of the motor and reduces the working noise. In addition, the stable and continuous power supply during the driving process can ensure that the reaction force on the stator core 1 when the stator core 1 generates magnetic pull is consistent with the direction of rotation. During steady-state driving, the force is evenly distributed, and it is not easy to generate jitter inside the stator core 1, which can improve the working stability and overall life of the motor.

[0090] (3) Compared with the traditional three-phase motor, the basic formula for the traditional three-phase motor design is: the number of motor teeth = (number of magnetic poles / 2)*3, that is, the number of teeth corresponding to the 8-pole magnetic ring is: (8 / 2)*3=12 teeth.

[0091] In the motor disclosed herein, assuming each tooth group 11 has one tooth 11', the total number of teeth 11' is Z, where Z = P * X. For a two-phase motor, if the stator core 1 also has 12 teeth 11', then the number of magnetic poles P = 12 / 2 = 6. By comparison, with the same number of teeth, the motor disclosed herein can reduce the number of magnetic poles P of the magnetic ring 21. For the same speed and power, two power switches are required to complete the rotation of a pair of magnetic poles, reducing the drive frequency and thus the driving difficulty.

[0092] (4) Compared with traditional three-phase motors, the stator assembly of traditional three-phase motors coming off the automated production line has two inlet and outlet wires, and the wires are irregular and messy. The production process requires flexible assembly stations, where the wires are manually cut to find the six wire ends, and then the wire ends are welded according to the star or triangle connection method, finally reserving the three outlet wire ends of UVW. This stator assembly has many crossed coils, making automated winding more difficult.

[0093] In the motor disclosed herein, the conductors 3 of the same phase are wound alternately, and the winding method is simple. Since the X-phase conductors 3 are independent of each other, the X-phase conductors 3 can be fully automated so that each has a first end and a second end after winding, which reduces the winding of wires and does not require manual trimming before entering the next process, thereby improving the degree of automation of winding, thereby improving production efficiency and winding success rate.

[0094] In this embodiment, the forward and reverse rotation of the motor can be achieved by adjusting the order of driving the X-phase wires 3. By passing the drive signals in sequence according to the 1 to X-phase wires 3, the motor can be rotated forward (forward rotation can be defined as counterclockwise or clockwise); by passing the drive signals in sequence according to the X to 1 phase wires 3, the motor can be reversed.

[0095] For example, for a two-phase motor, if the drive signal is supplied first at X1 and then at X2, the motor rotates forward. However, if the drive signal is supplied first at X2 and then at X1, the motor rotates reversely.

[0096] For example, for a three-phase motor, if the drive signal is applied in the order of X1-X2-X3, the motor rotates forward. However, if the drive signal is applied in the order of X3-X2-X1, the motor rotates reversely.

[0097] In some embodiments, as shown in FIG. 2 and FIG. 5 , the tooth set 11 includes a single tooth 11 ′, and the wire 3 is wound around the tooth 11 ′ to form a coil 31 on the tooth 11 ′.

[0098] For example, all tooth groups 11 in the stator core 1 include only a single tooth 11', as shown in Figure 2, the tooth 11' includes a neck 111 and a boot 112. Optionally, the cross-section of the neck 111 can be circular, elliptical, triangular, rectangular or other polygonal, and the boot 112 is connected to the neck 111 and can be in an arc shape. The boot 112 is connected to the radial end of the neck 111, such as the radial inner end or the radial outer end. The coil 31 is wound on the neck 111, and the radial ends are respectively blocked and limited by the yoke 12 and the boot 112.

[0099] As shown in FIG2 , all teeth 11 ′ have the same shape and size, and are spaced and evenly distributed along the circumference of the stator core 1 ; as shown in FIG13 , the teeth 11 ′ corresponding to different phase conductors 3 have different sizes, ie, different circumferential coverage angles.

[0100] This structure is relatively simple to wind, easy to control the tightness of the winding, and has low requirements for the winding process.

[0101] In some embodiments, the teeth set 11 includes at least two teeth 11', which are spaced apart along the circumference of the stator core 1. The conductor 3 is wound around the at least two teeth 11' to form a coil 31 on the at least two teeth 11'. Specifically, all teeth 11' in the teeth set 11 are wound around the same phase conductor 3 as a whole, forming a coil 31 on the teeth set 11.

[0102] Typically, to increase motor torque, the arc length of the boot 112 is increased. However, the coil 31 wound around the neck 111 only covers the neck 111, failing to utilize the space between the necks 111 of adjacent teeth 11'. This embodiment, by winding the coil 31 around at least two teeth 11', allows the coil 31 to fully cover the space between adjacent tooth groups 11 in the circumferential direction of the stator core 1, thereby increasing magnetic flux strength and facilitating increased motor torque.

[0103] Optionally, some of the tooth groups 11 in the stator core 1 include only a single tooth 11', and the remaining tooth groups 11 include at least two teeth 11'. This structure can be flexibly configured according to the performance requirements of the motor.

[0104] In some embodiments, each phase conductor 3 is configured to receive an independent drive signal. Thus, the drive signals received by all phase conductors 3 are independent of one another. For example, the drive signal can be a continuous sine wave, a discontinuous sine wave, or a square wave. Reversing the drive signal causes the magnetic force generated by the coil 31 to reverse direction.

[0105] In this embodiment, the drive signals passed through each phase conductor 3 of the motor are independent of each other. The drive signals only need to have a certain phase difference, which enables each phase conductor 3 to realize full-time power supply and rotation of the rotor 2. The utilization rate of the winding and the stator core can reach 100%, thereby increasing the maximum working efficiency of the motor. Moreover, the power supply of each phase conductor 3 does not need to be frequently switched, which can reduce operating noise. In addition, the stable and continuous power supply during the driving process can ensure that the reaction force on the stator core 1 when the stator core 1 generates magnetic pull is consistent with the direction of rotation. During steady-state drive, the force is evenly distributed, and it is not easy to generate jitter inside the stator core 1, which can improve the working stability and overall life of the motor.

[0106] In some embodiments, in the radial direction of the stator core 1, the winding direction of each coil 31 formed by at least two phase conductors 3 is consistent. For example, as shown in FIG2 , all coils 31 are wound radially from the inside to the outside. Alternatively, all coils 31 may be wound radially from the outside to the inside.

[0107] The winding method of this embodiment does not need to consider the winding form of a specific phase conductor 3, and adopts a uniform winding direction in the radial direction, which is conducive to improving the efficiency of automated winding.

[0108] In some embodiments, the starting winding position of each coil 31 formed by at least two phase conductors 3 is located on the side away from the rotor 2. As shown in Figure 2, for an outer rotor motor, the magnetic ring 21 is arranged outside the stator core 1, and the starting winding position of each coil 31 is located radially inward. In other structural forms, the stator core 1 is annular, the magnetic ring 21 is located inside the stator core 1, and the starting winding position of each coil 31 is located radially outward.

[0109] In this embodiment, taking into account that the rotor side is provided with other components such as the magnetic ring 21 and the Hall, the starting winding position is located on the side away from the rotor 2 to avoid the wiring affecting the moving parts.

[0110] In some embodiments, in the radial direction of the stator core 1, the first and second ends of at least two phase conductors 3 are led out from the same side of the teeth set 11. For example, all the first and second ends may be led out from the radial outside or radial inside of the stator core 1.

[0111] In addition, the first end and the second end are both led out from the tooth groove formed between adjacent tooth groups 11 .

[0112] This embodiment allows the first end and the second end of each phase conductor 3 to be conveniently led to the electrical interface of the motor, and can make the lead wires of the stator core 1 more neatly and orderly arranged in the motor.

[0113] In some embodiments, in the circumferential direction of the stator core 1 , all the first ends and the second ends are led out from a plurality of adjacent tooth groups 11 .

[0114] Figure 2 shows the stator core 1 of a two-phase motor. The first end of the wire 3 is the input end, and the second end is the output end. The two input ends are X1-IN and X2-IN, and the two output ends are X1-OUT and X2-OUT. The two input ends and the two output ends are led out from four adjacent tooth groups 11. For example, the lead-out order along the circumferential direction is X2-IN, X1-IN, X2-OUT, and X1-OUT.

[0115] Figure 10 shows the stator core 1 of a three-phase motor. The first end of the wire 3 is the input end, and the second end is the output end. The three input ends are X1-IN, X2-IN, and X3-IN, and the three output ends are X1-OUT, X2-OUT, and X3-OUT. The three input ends and the three output ends are led out from six adjacent tooth groups 11. For example, the lead-out order along the circumferential direction is X3-IN, X2-IN, X1-IN, X3-OUT, X2-OUT, and X1-OUT.

[0116] In this embodiment, all the first ends and the second ends are distributed in a relatively close area. In automated winding, it is easier to control the layout positions of multiple leads, and it is also convenient to lead multiple leads to the electrical interface of the motor in an orderly manner, which is conducive to mass production.

[0117] In some embodiments, the winding directions of the coils 31 of at least two phase conductors 3 located at the same sequence number from the first end along the circumference of the tooth set 11 are consistent.

[0118] Taking a two-phase motor as an example, Figure 2 is a schematic diagram of a two-phase motor. The first end is the input end, and the second end is the output end. The two input ends are X1-IN and X2-IN, respectively, and the two output ends are X1-OUT and X2-OUT, respectively. There are eight tooth groups 11. The X1-phase conductor 3 is wound around four tooth groups 11, sequentially numbered 1, 2, 3, and 4. The X2-phase conductor 3 is wound around four tooth groups 11, sequentially numbered 1, 2, 3, and 4. The X1 and X2-phase conductors 3 have the same winding direction on the tooth group 11 numbered 1, the same winding direction on the tooth group 11 numbered 2, the same winding direction on the tooth group 11 numbered 3, and the same winding direction on the tooth group 11 numbered 4.

[0119] Therefore, X1-IN and X2-IN are both led out from adjacent tooth slots 11 on the same side of the stator core 1 circumferentially, that is, from adjacent tooth slots. X1-OUT and X2-OUT are also led out from adjacent tooth slots 11 on the same side of the stator core 1 circumferentially, that is, from adjacent tooth slots. X1-IN and X2-OUT are led out from the same tooth slot.

[0120] This embodiment makes the winding patterns of at least two-phase conductors 3 consistent, which is equivalent to copying the winding method of a single-phase conductor 3 , thereby simplifying the winding method and improving the efficiency of automated winding.

[0121] In other embodiments, the winding directions of the coils 31 of at least one group of adjacent two-phase conductors 3 located at the same sequence number from the first end along the circumference of the tooth group 11 are opposite.

[0122] Taking a two-phase motor as an example, based on Figure 2, if the winding directions of X1 and X2 are opposite, X1-IN and X2-IN need to be led out from the tooth slots on different sides of the adjacent tooth groups 11 along the circumference of the stator core 1, that is, there is one tooth slot between the tooth slots from which X1-IN and X2-IN are respectively led out; X1-OUT and X2-OUT also need to be led out from the tooth slots on different sides of the adjacent tooth groups 11 along the circumference of the stator core 1, that is, from the same tooth slot.

[0123] In the alternating power control mode, the two output terminals X1-OUT and X2-OUT need to be short-circuited to connect to the three half-bridge drive circuits on the circuit board. This winding method allows the two output terminals to be led out from the same tooth slot, facilitating short-circuiting and better adapting to the layout of the circuit board under the alternating power control mode.

[0124] In some embodiments, at least two phase conductors 3 are wound in sequence from the 1st to the Xth phase along the circumference of the stator core 1; the conductors 3 for inputting the driving signal include the i-th phase conductor 3 and the k-th phase conductor 3, and the phase difference between the driving signal of the i-th phase conductor 3 and the driving signal of the k-th phase conductor 3 is Among them, 1≤i<k≤X.

[0125] In the same stator core 1, the tooth group 11 of the x-phase conductor 3 and the adjacent tooth groups 11 on both sides have a gap at the closest position, and the gap has a center position in the circumferential direction of the stator core 1; in all the gaps formed by the Z tooth groups 11, the central angle corresponding to the arc between the center position of the x-phase conductor 3 and the adjacent center position in the circumferential direction of the stator core 1 is β X , and β X The corresponding sector includes at least part of the teeth set 11 of the x-th phase conductor 3. Optionally, β X The value range is 1° to 180°.

[0126] Specifically, as shown in Figures 1 to 18, the stator core 1 is provided with only one, and the winding order of at least two phase conductors 3 is 1, ...x..., X, 1 < x < X. The two phase conductors 3 that carry the drive signal may be adjacent or non-adjacent. The tooth group 11 of the x-phase conductor 3 and the adjacent tooth groups 11 on both sides have a gap at the closest position. For example, the tooth group 11 includes only a single tooth 11', and the tooth 11' includes a neck 111 and a boot 112. The boot 112 is connected to the radial end of the neck 111 to form a T-shaped structure, and a gap is formed between the boots 112 of adjacent teeth 11'. The β of the x-phase conductor 3 X The corresponding sector only includes one tooth group 11 where the phase conductor 3 is located.

[0127] θ ik is the phase difference of the program drive. Controlling the driver reversal within this degree will cause the magnetic force generated by the coil 31 to commutate, and β X This corresponds to the phase difference during program driving, which ensures that the corresponding rotor magnetic field is also at the commutation position when the program driving signal is commutated.

[0128] For a two-phase motor, i=1, k=2, θ ik =θ 12 is the phase difference between the X1 phase and X2 phase drive signals,

[0129] For three-phase motors, there are three possible value options:

[0130] i=1,k=2,θ ik =θ 12 is the phase difference between the X1 phase and X2 phase drive signals,

[0131] i=2,k=3,θ ik =θ 23 is the phase difference between the X2-phase and X3-phase drive signals,

[0132] i=1,k=3,θ ik =θ 13 is the phase difference between the X1 phase and the X3 phase drive signal. The two phases of the drive signal are not adjacent.

[0133] This embodiment can conveniently calculate the phase difference between drive signals input in different phases based on the structural parameters of the magnetic ring 21 and the stator core 1, thereby accurately and stably controlling the rotation process of the motor.

[0134] In some embodiments, as shown in Figures 20 to 23, multiple stator cores 1 are stacked in the axial direction, and each stator core 1 includes at least one phase conductor 3. In the circumferential direction of the stator core 1, the tooth groups 11 of the multiple stator cores 1 are staggered.

[0135] The number of tooth sets 11 in multiple stator cores 1 can be the same or different. In this structure, the total number of tooth sets 11 in all stator cores 1 is Z, and the total number of phases of all conductors 3 is X, where Z = P * X. If the multiple stator cores 1 are projected onto a reference plane perpendicular to the axis, this is equivalent to a single stator core 1 having Z tooth sets 11 and X-phase conductors 3. The thickness of the magnetic ring 21 can be consistent with the sum of the axial dimensions of the multiple stator cores 1. A gap exists between adjacent stator cores 1 to accommodate the conductors 3 wound on adjacent stator cores 1. To ensure insulation, the conductors 3 on adjacent stator cores 1 do not touch.

[0136] For example, two stator cores 1 are provided, one phase conductor 3 is wound around each stator core 1, and the winding directions along the circumference of the tooth groups 11 on adjacent tooth groups 11 in the same stator core 1 are opposite, thereby serving as a two-phase motor; or three stator cores 1 are provided, one phase conductor 3 is wound around each stator core 1, thereby serving as a three-phase motor; or two stator cores 1 are provided, one stator core 1 is wound around one phase conductor 3, and the other stator core 1 is wound around two phase conductors 3, thereby serving as a three-phase motor.

[0137] As shown in FIG20 , two stator cores 1 are stacked in the axial direction. To facilitate installation and ensure the coaxiality of the two stator cores 1 , the connecting shaft 4 passes through the central through holes of the two stator cores 1 .

[0138] Figure 21 is a schematic diagram of the X1 phase conductor 3 wound on one of the stator cores 1. In this stator core 1, the winding directions of the coils 31 on two adjacent tooth groups 11 along the circumference of the tooth group 11 are opposite, and X1-IN and X1-OUT are led out from the two adjacent tooth groups 11.

[0139] Figure 22 is a schematic diagram of winding the X2 phase conductor 3 on another stator core 1. In this stator core 1, the winding directions of the coils 31 on two adjacent tooth groups 11 along the circumference of the tooth group 11 are opposite, and X2-IN and X2-OUT are led out from the two adjacent tooth groups 11.

[0140] Figure 23 is a schematic diagram of the structure of two stator cores 1 stacked axially. The axial length of the magnetic ring 21 covers both stator cores 1, and the tooth groups 11 of the two stator cores 1 are staggered circumferentially. Specifically, each tooth group 11 includes a tooth 11'. When the two stator cores 1 are projected axially onto the same plane, the necks 111 of two adjacent teeth 11' and the coils wound thereon are completely staggered circumferentially. The boots 112 of two adjacent teeth 11' overlap circumferentially. X1-IN, X2-IN, X1-OUT, and X2-OUT extend from four adjacent teeth 11' on the two stator cores 1.

[0141] This type of motor still satisfies Z=P*X. For example, the number of poles of the magnetic ring 21 is P=8, the number of phases of the conductor 3 is X=2, the number of tooth groups 11 of each stator core 1 is 8, and the total number of tooth groups 11 of the two stator cores 1 is Z=16.

[0142] For this type of motor, when determining β X When the gap is formed between two adjacent tooth groups 11 in the same stator core 1, in all the gaps formed by the Z tooth groups 11, the central angle of the arc between the center position of the x-th phase conductor 3 and the adjacent center position in the circumferential direction of the stator core 1 is β X , used to form β X The two gaps are located in the two stator cores 1. Moreover, β X The corresponding sector includes both the tooth group 11 of the x-th phase conductor 3 and the tooth groups 11 of the other phase conductors 3 .

[0143] While maintaining performance, the motor of this embodiment can reduce the number of tooth groups 11 in each stator core 1. This increases the spacing between adjacent tooth groups 11, reducing the difficulty of machining a single stator core 1. Furthermore, the number of winding phases per stator core 1 is also reduced, further reducing the winding difficulty of a single stator core 1. To improve motor performance, the motor's axial dimensions can be expanded without increasing its radial dimensions, thereby improving performance parameters.

[0144] In some embodiments, the drive signal strength supplied to the conductors 3 of all phases is consistent throughout the entire target speed range of the rotor 2. The drive signal strength is characterized by the amplitude of the drive signal. Furthermore, the drive signal frequency supplied to the conductors 3 of all phases is the same.

[0145] The driving method of this embodiment is mainly suitable for situations where the number of motor phases is small. In order to meet the working index requirements, all phases must be energized under any working conditions to fully utilize the capacity of the motor.

[0146] In some embodiments, when the target torque of the rotor 2 is higher than the first preset torque, the strength of the driving signal passed through each phase conductor 3 is consistent;

[0147] When the target torque of the rotor 2 is not higher than the first preset torque, the drive signals passed into the conductors 3 of some phases have a preset strength, and the drive signals passed into the conductors 3 of the remaining phases are lower than the preset strength or are not driven.

[0148] For example, when a motor has a large number of phases, such as five, high torque is generally required at low speeds (i.e., the target torque is higher than a first preset torque). Drive signals can be applied simultaneously to all five phase conductors 3. At high speeds, lower torque is generally required (i.e., the target torque is no higher than the first preset torque). Phases 1, 3, and 5 of the five-phase conductors 3 can be powered, while phases 2 and 4 are either unpowered or driven with a weak current. Torque is related to the number of drive phases and the amplitude of the drive signal, while speed is related to the frequency of the drive signal. This type of motor can be used in automotive power motors, enabling specific drive modes by increasing the number of phases, thereby resolving the technical challenge of difficult power motor selection.

[0149] The driving method of this embodiment is mainly suitable for situations where the load torque range is relatively wide. By increasing the number of phases, partial phase drive or full phase drive can be flexibly selected according to the torque requirements during actual operation, which enables the motor to meet the performance requirements under different working conditions and reduces the difficulty of motor selection.

[0150] In this embodiment, the strength (represented by amplitude) of the drive signal transmitted to each phase conductor 3 during motor operation is allowed to vary, but the frequency of the drive signal transmitted to each phase conductor 3 is equal. By transmitting drive signals of different strengths to each phase conductor 3, in addition to adapting to different operating conditions as described above, efficiency can also be maximized during control. Specifically, the motor has loaded inertia during operation. Reducing the drive current at an appropriate time will reduce the drive torque. The loaded inertia can compensate for the motor's output torque. This control method can maximize efficiency and reduce power consumption.

[0151] In some embodiments, as shown in FIG6 , the motor has a first working mode. In the first working mode, each phase conductor 3 is energized at all times, and the driving signals between adjacent phase conductors 3 have a phase difference.

[0152] This motor uses a cross-current drive mode. Each phase conductor 3 receives a continuous drive signal, and the drive signals between adjacent phase conductors 3 have a phase difference. The drive signal can be a sine wave, square wave, or other continuous waveform. Different drive waveforms can be achieved through an electronic commutator, such as a thyristor, MOSFET, or IGBT. The commutation phase difference between the drive signals can range from 1° to 180°. The advantages of using a sine wave drive are low drive noise, good linearity, and higher efficiency under high torque or acceleration conditions. The advantages of using a square wave drive are a simple and low-cost position sensor structure, requiring only logical processing of the position signal, which can increase output torque.

[0153] The windings of the motor in this embodiment are continuously energized, and the utilization rate of the windings and stator core can reach 100%, thereby increasing the operating efficiency of the motor. Moreover, the energization of each phase conductor 3 does not need to be frequently switched, which can reduce operating noise. In addition, the stable and continuous energization during the driving process can ensure that the reaction force on the stator core 1 when the stator core 1 generates magnetic pull is consistent with the direction of rotation. During steady-state driving, the force is evenly distributed, and it is less likely to cause vibration within the stator core 1, which can improve the operating stability and overall life of the motor.

[0154] In some embodiments, as shown in FIG. 7 and FIG. 8 , the motor has a second operating mode. In the second operating mode, each phase conductor 3 is intermittently energized, and the driving signals between adjacent phase conductors 3 have a phase difference.

[0155] This type of motor uses an alternating current drive mode, with each phase conductor 3 receiving a discontinuous drive signal, and the drive signals between adjacent phase conductors 3 having a phase difference. For example, in a two-phase motor, as shown in Figure 7 , the drive signal is a discontinuous sine wave; as shown in Figure 8 , the drive signal is a square wave.

[0156] 7 , the driving signal for the first phase conductor can be obtained by advancing the commutation position of the continuous sinusoidal wave signal by a phase angle of f1′ and lagging it by a phase angle of f1″, and the driving signal for the second phase conductor can be obtained by advancing the commutation position of the continuous sinusoidal wave signal by a phase angle of f2′ and lagging it by a phase angle of f2″.

[0157] The drive signal provided to each phase conductor 3 is preferably commutated when the boot portion 112 of the tooth set 11 around which the phase conductor 3 is wound is aligned with the critical point of the magnetic pole. However, in practice, due to various reasons (for example, errors in the average distribution angle of the magnetic ring of the brushless motor due to production; for example, errors in the drive detection of the brushless motor), it may not be possible to accurately control the commutation point to occur at the moment when it is aligned with the critical point of the magnetic pole. Instead, it may be ahead of or behind this moment to a certain extent. This will cause the winding to perform useless work during the period ahead of or behind this moment, thereby reducing the efficiency of the brushless motor.

[0158] By providing a discontinuous drive signal, the wasted work done by the winding can be reduced, thereby improving the efficiency of the brushless motor.

[0159] 8 , providing a square wave drive signal is simpler to control. Therefore, in the alternating energization mode, using a square wave drive signal to drive the brushless motor can further simplify the control.

[0160] The intermittent energization of the motor windings in this embodiment increases the motor's output torque, simplifies control, and, with specific design matching, reduces drive control costs. Although this motor slightly reduces the utilization rate of the stator core and windings, it is still superior to brushed motors currently on the market, most of which have a stator core and winding utilization rate of only about 30%.

[0161] For the aforementioned cross-current and alternating current drive modes, the motor control procedures and Hall effect detection locations differ, the calculations and considerations for the motor's internal windings differ, and the motor's output power also differs. Therefore, each motor generally uses one drive mode. To meet specific motor needs, if cost is not a priority, a combination of alternating current and cross-current drive modes can be used. For example, for power motors, alternating current can be used to increase torque at low speeds, while cross-current can be used to improve efficiency at high speeds, thereby more comprehensively meeting the motor's usage requirements.

[0162] It should be understood that the above merely schematically illustrates that the driving signal in the cross-energization driving mode conforms to a sine function, while the waveform of the driving signal in the alternating-energization driving mode is a square wave, and the embodiments of the present disclosure are not limited thereto.

[0163] In some embodiments, the brushless motor can be driven by one of two driving modes: cross-current and alternating current. In other embodiments, the brushless motor can be driven by a combination of cross-current and alternating current.

[0164] According to the positional relationship between the stator core 1 and the rotor 2 , three embodiments of motors with different structures are given below.

[0165] In some embodiments, as shown in Figures 1 and 2 , the magnetic ring 21 is sleeved outside the stator core 1. The tooth 11' includes a neck portion 111 and a boot portion 112 connected to form a T-shape. The neck portion 111 is connected to the outer peripheral wall of the yoke portion 12. The boot portion 112 is located at the radially outer end of the neck portion 111, with a gap between the boot portion 112 and the magnetic ring 21.

[0166] The outer rotor motor of this embodiment can achieve a larger torque under a certain circumferential size because the arm of the magnetic field force generated by energizing the coil 31 is larger.

[0167] In some embodiments, as shown in Figures 4 and 5 , the stator core 1 is annular and is sleeved outside the magnetic ring 21. The tooth 11' includes a neck portion 111 and a boot portion 112 connected to form a T-shape. The neck portion 111 is connected to the inner circumferential wall of the yoke 12, and the boot portion 112 is located at the radially inner end of the neck portion 111, with a gap between the boot portion 112 and the magnetic ring 21.

[0168] The inner rotor motor of this embodiment can achieve a relatively high rotational speed while maintaining a certain circumferential dimension. Furthermore, since the coil 31 is located outside the magnetic ring 21, heat dissipation is improved and maintenance is facilitated. For example, the inner rotor motor can be used in applications such as electric vehicles that require high heat dissipation and easy assembly.

[0169] In some embodiments, as shown in FIG. 15 to FIG. 19 , the stator core 1 and the magnetic ring 21 are axially overlapped, and the magnetic ring 21 at least partially covers the coil 31 in the radial direction of the stator core 1 .

[0170] Figure 15 is a schematic diagram of the structure of the stator core 1. The yoke 12 is an annular, disc-shaped structure, with multiple tooth groups 11 disposed at the ends of the yoke 12. For example, each tooth group 11 includes only a single tooth 11'. Each tooth 11' is generally trapezoidal in shape, with rounded corners and arc-shaped radially inner and outer edges. Conductors 3 are wound around the outer circumference of the teeth 11'.

[0171] Figure 16 is a schematic diagram of the magnetic ring structure, and Figure 17 illustrates the axially stacked arrangement of the stator core 1 and the magnetic ring 21. The magnetic ring 21 at least partially covers the coil 31 in the radial direction of the stator core 1. Therefore, the magnetic ring 21 needs to be relatively wide. To ensure that the magnetic field generated by the coil 31 when energized can effectively act on the magnetic ring 21, the magnetic ring 21 completely covers the coil 31 in the radial direction of the stator core 1. The rotating shaft 22 is connected to the center of the magnetic ring 21, and both ends of the rotating shaft 22 extend beyond the stator core 1 and the magnetic ring 21.

[0172] The planar motor of this embodiment is relatively small in size and has a flat and thin overall shape. It can be used in situations where the installation size is relatively limited, and can achieve high torque and high power.

[0173] In some embodiments, as shown in FIG18 , magnetic rings 21 are provided on both sides of the stator core 1 in the axial direction; as shown in FIG19 , the stator core 1 is provided on both sides of the magnetic ring 21 in the axial direction; or, the motor includes a plurality of stator cores 1 and a plurality of magnetic rings 21, and the stator core 1 and the magnetic rings 21 are alternately arranged in the axial direction, which satisfies both the requirement that the stator core 1 is provided with magnetic rings 21 on both sides in the axial direction and the requirement that the stator core 1 is provided with magnetic rings 21 on both sides in the axial direction.

[0174] The motor of this embodiment can achieve greater torque, thereby improving power density.

[0175] Secondly, the present disclosure provides a device including the motor of the above embodiment. For example, the device may relate to the fields of electrical servo drive, information processing, transportation, household appliances, consumer electronics, national defense, and special-purpose applications.

[0176] Since the motor of the embodiment of the present disclosure has better comprehensive performance, for example, it can increase torque and power, improve work efficiency, improve work stability and life, reduce working noise, reduce the number of poles when the number of teeth is the same, thereby reducing the driving difficulty, and improve the degree of winding automation and efficiency, etc., this type of motor can well meet the driving needs of different equipment in different fields and is easier to select.

[0177] Finally, the present disclosure provides a method for manufacturing a motor based on the above embodiment. Referring to FIG. 2 , in some embodiments, the manufacturing method includes:

[0178] Wire supply steps: provide a wire 3;

[0179] Winding step: Winding the wire 3 on the tooth groups 11 in different phase sequences until a coil 31 is formed on each tooth group 11; among all coils 31 of the wire 3 in the same corresponding tooth group, the number of tooth groups 11 between the coils 31 on two adjacent tooth groups 11 is X-1, and the winding directions of the coils 31 on the two adjacent tooth groups 11 along the circumference of the tooth group 11 are opposite;

[0180] Disconnection step: disconnect the conductor 3 at the connection point of adjacent phase sequences, so that the total number of phases of the conductor 3 is X, and each phase conductor 3 has an independent first end and second end.

[0181] For example, in the two-phase motor shown in Figure 2, a wire 3 is wound starting at X1-IN, sequentially around each tooth group 11. The winding directions of adjacent tooth groups 11 are opposite along the circumference of the tooth group 11. After a full circumference of winding is completed, the wire 3 is led out from X1-OUT. The wire 3 then continues winding at X2-IN, still sequentially around each tooth group 11, until it is led out from X2-OUT. Finally, the connection between X1-OUT and X2-IN is disconnected, forming the X1 and X2 phase wires 3.

[0182] This embodiment uses a single conductor 3 to wind all phases without interruption, facilitating automated winding. Furthermore, the conductors 3 of the same phase are wound alternately, simplifying the winding method. Since the conductors 3 of each phase are independent of each other, each phase conductor 3 can be fully automated to have a first end and a second end after winding. This reduces the amount of wire coiling and eliminates the need for manual trimming before proceeding to the next step. This improves the degree of automation in winding, thereby increasing production efficiency and the success rate of winding.

[0183] Some specific embodiments of the motor disclosed herein are given below.

[0184] In the first embodiment, as shown in Figures 1 and 2 , the motor includes a stator core 1. The stator core 1 includes a yoke 12 and multiple tooth groups 11. The multiple tooth groups 11 are evenly spaced along the circumference of the stator core 1 and connected to the outer periphery of the yoke 12. The yoke 12 is annular in shape. Each tooth group 11 includes a single tooth 11'. The tooth 11' includes a neck 111 and a shoe 112. The shoe 112 is connected to the radially outer end of the neck 111 to form a T-shaped structure.

[0185] The magnetic ring 21 is coaxially sleeved outside the stator core 1. This type of outer rotor motor has a larger force arm due to the magnetic field force generated by energizing the coil 31, and can achieve a larger torque under the condition of a certain circumferential size.

[0186] Two-phase conductors 3 are wound around teeth 11' to form coils 31 on teeth 11'. Each phase conductor 3 has independent first and second ends. For example, the X1-phase conductor 3 has X1-IN and X1-OUT, and the X2-phase conductor 3 has X2-IN and X2-OUT. For each phase conductor 3, the number of teeth 11' separating two adjacent coils 31 is one. The winding directions of two adjacent coils 31 along the circumference of the tooth 11' are opposite, and the two adjacent coils 31 are connected by a connecting segment 32. X2-IN, X1-IN, X2-OUT, and X1-OUT extend from four adjacent teeth 11' along the circumference.

[0187] For example, when the number of poles of the magnetic ring 21 is P=4 and the total number of phases of the conductor 3 is X=2, the remaining structures and drive parameters are designed as follows:

[0188] The number of teeth 11 ′ Z=P*X=4x2=8;

[0189] The monopole angle of the magnetic ring 21 is β=360° / P=360° / 4=90°;

[0190] The central angle of the arc between the gaps on both sides of the teeth 11' where the X1 and X2 phases are located and the center position of the stator core 1 in the circumferential direction is β1 = β2 = 45°;

[0191] The phase difference θ between the two-phase drive signals 12 =2x45°=90°.

[0192] Based on the above structure, during winding, the X1-phase conductor 3 corresponds to teeth 11' numbered 1, 3, 5, and 7, and is wound alternately in opposite directions along the circumference of the teeth 11', forming two lead wires, X1-IN and X1-OUT. The X2-phase conductor 3 corresponds to teeth 11' numbered 2, 4, 6, and 8, and is wound alternately in opposite directions along the circumference of the teeth 11', forming two lead wires, X2-IN and X2-OUT. These four lead wires correspond to the four connection ports for the two-phase drive on the driver board.

[0193] As shown in Figure 6, the drive signal for a two-phase motor is a continuous sine wave. For example, the two sine waves can have the same amplitude and frequency, but a 90° phase difference. This phase difference can be precisely controlled through software. Furthermore, the software pre-calculates the motor drive data and then outputs the drive waveform corresponding to the motor speed requirements, precisely controlling the independent power supply of each circuit.

[0194] Each phase conductor 3 is energized at all times, using a cross-current drive mode. Two independent waveforms, each with a 90° phase difference, switch once to achieve rotation of a pair of N-pole rotors. This simple drive and stable switching improve the motor's operating efficiency, stability, and overall lifespan, while reducing operating noise. It can be used directly with varying loads within the rated operating range without debugging. The drive signal direction switches four times within each phase cycle.

[0195] As shown in FIG7 , the driving signal of the two-phase motor is a discontinuous sine wave.

[0196] As shown in FIG8 , the driving signal of the two-phase motor is an intermittent square wave, and the driving mode is alternating power supply, which can increase the output torque of the motor, simplify the control difficulty, and reduce the cost.

[0197] The motor in this disclosure is driven by AC power. To achieve two sets of AC input, there are three solutions:

[0198] 1. By using the principle of capacitor phase shifting on the AC output, the single-phase AC is converted into two-phase AC with a 90° phase difference, which can directly drive the motor. At this time, the AC frequency is 50Hz, so the motor speed is constant in this solution. To control the motor speed, the AC frequency must be changed, which makes speed regulation more difficult.

[0199] 2. The AC power is converted into a DC power of a predetermined voltage through an AC-DC switching power supply, and then converted into an AC power of a predetermined voltage through a MOS tube control. The AC power is then divided into two AC power paths with a 90° phase difference to power the motor, thereby achieving drive. This scheme is relatively simple to control the speed.

[0200] 3. Convert AC power into 310V DC power through a rectifier bridge, then invert it into a specified voltage AC power through a MOS tube control, and then divide it into two AC power with a phase difference of 90° to power the motor, so as to achieve drive. This solution is also simple to control the speed.

[0201] In the second embodiment, as shown in Figures 4 and 5 , the difference from the first embodiment lies in that the neck portion 111 is connected to the inner circumferential wall of the yoke portion 12, and the shoe portion 112 is located at the radially inner end of the neck portion 111. This inner rotor motor can achieve a higher speed while maintaining a certain circumferential dimension. Furthermore, because the coil 31 is located outside the magnetic ring 21, heat dissipation is improved and maintenance is facilitated. The winding and drive methods of the second embodiment can be referred to in the first embodiment.

[0202] In the third embodiment, as shown in Figures 9 and 10 , the difference from the first embodiment lies in that three-phase conductors 3 are wound around teeth 11' to form coils 31 on teeth 11'. Each phase conductor 3 has independent first and second ends. For example, the X1-phase conductor 3 has X1-IN and X1-OUT, the X2-phase conductor 3 has X2-IN and X2-OUT, and the X3-phase conductor 3 has X3-IN and X3-OUT. For each phase conductor 3, the number of teeth 11' separating two adjacent coils 31 is two. The winding directions of adjacent coils 31 along the circumference of the tooth 11' are opposite, and the adjacent coils 31 are connected by a connecting segment 32. X3-IN, X2-IN, X1-IN, X3-OUT, X2-OUT, and X1-OUT extend circumferentially from six adjacent tooth groups 11.

[0203] For example, when the number of poles of the magnetic ring 21 is P=4 and the total number of phases of the conductor 3 is X=3, the remaining structures and drive parameters are designed as follows:

[0204] The number of teeth 11 ′ Z=P*X=4x3=12;

[0205] The monopole angle of the magnetic ring 21 is β=360° / P=360° / 4=90°;

[0206] The central angle of the arc between the gaps on both sides of the teeth 11' where the X1, X2 or X3 phases are located and the central position of the stator core 1 in the circumferential direction is β1 = β2 = β3 = 30°;

[0207] As shown in Figure 11, in the three-phase drive signal, the phase difference θ between the X1 and X2 phases is 12 =2x30°=60°; Phase difference θ between X2 and X3 23 =2x30°=60°; Phase difference θ between X1 and X3 13 =2x60°=120°.

[0208] The drive signal for the three-phase motor is a continuous sine wave. The amplitude and frequency of the three-phase sine waves can be the same, and the phase difference between the drive signals of two adjacent phases is 60 degrees. Each phase conductor 3 is energized at all times, and the drive mode is cross-energization.

[0209] As shown in Figure 12, the drive signal for the two-phase motor is an intermittent square wave. The amplitude and frequency of the three-phase square wave can be the same. The phase difference between the three-phase drive signals is calculated in the same manner as in Figure 11, with the phase difference between adjacent two-phase drive signals being 60°. Each phase conductor 3 is energized intermittently, and the drive mode is alternating energization.

[0210] Compared with two-phase motors, three-phase motors can achieve greater driving torque. During operation, all three-phase conductors 3 can be energized, or partial phase conductors 3 can be energized according to actual torque requirements.

[0211] In the fourth embodiment, as shown in Figures 13 and 14 , the difference from the first embodiment is that the spaces occupied by the teeth 11' corresponding to the conductors 3 of different phases differ in the circumferential direction of the stator core 1. That is, the teeth 11' corresponding to the conductors 3 of different phases are unevenly distributed circumferentially along the stator core 1, but the teeth 11' corresponding to the conductors 3 of the same phase are evenly distributed circumferentially along the stator core 1. For example, the circumferential length of the shoe 112 corresponding to the tooth 11' of the X1-phase conductor 3 is smaller than the circumferential length of the shoe 112 corresponding to the tooth 11' of the X2-phase conductor 3.

[0212] The number of teeth 11 ′ Z=P*X=4x2=8;

[0213] The monopole angle of the magnetic ring 21 is β=360° / P=360° / 4=90°;

[0214] The central angles of the arcs between the gaps on both sides of the teeth 11' where the X1 and X2 phases are located and the central positions of the stator core 1 in the circumferential direction are β1 = 22.5° and β2 = 67.5°;

[0215] The phase difference θ between the two-phase drive signals 12 =2x22.5°=45°.

[0216] As shown in Figure 14, the drive signal for a two-phase motor is a continuous sinusoidal wave. For example, the two phases can have the same amplitude and frequency, with a 45° phase difference. Each phase conductor 3 is energized throughout the entire drive cycle, using a cross-current drive mode. This increases motor efficiency, improves operational stability and overall lifespan, and reduces operating noise. The direction of the drive signal switches four times during each phase cycle.

[0217] The fifth embodiment, shown in Figures 15 to 19 , differs from the first embodiment in that a yoke 12 has an annular, disc-shaped structure, and multiple tooth groups 11 are provided at the end of the yoke 12. For example, each tooth group 11 includes only a single tooth 11'. Each tooth 11' is generally trapezoidal in shape, with the four corners of the trapezoid being rounded and the radially inner and outer edges being arc-shaped. The conductor 3 is wound around the outer circumference of the tooth 11'.

[0218] Figure 16 is a schematic diagram of the magnetic ring structure, and Figure 17 illustrates the axially stacked arrangement of the stator core 1 and the magnetic ring 21. The magnetic ring 21 at least partially covers the coil 31 radially of the stator core 1. To ensure that the magnetic field generated by energizing the coil 31 effectively acts on the magnetic ring 21, the magnetic ring 21 completely covers the coil 31 radially of the stator core 1. The outer diameters of the stator core 1 and the magnetic ring 21 can be the same. This planar motor is compact, with a flat and thin overall shape, making it suitable for applications with limited installation dimensions and capable of achieving high torque and power.

[0219] As shown in FIG18 , a magnetic ring 21 is provided on both sides of the stator core 1 along the axial direction; as shown in FIG19 , a stator core 1 is provided on both sides of the magnetic ring 21 along the axial direction; or, the motor includes multiple stator cores 1 and multiple magnetic rings 21, and the stator cores 1 and the magnetic rings 21 are alternately arranged along the axial direction.

[0220] For each of the above embodiments, in addition to the advantages given above, this type of motor does not require the motor, drive circuit board, driver and load to be debugged and developed accordingly. By selecting the speed and power of a motor, the corresponding drive control board can be selected to achieve maximum efficiency drive. Because the drive signal of this motor corresponds to the speed and magnetic ring, that is, the precise commutation is comprehensively judged by the Hall sensor and the program in the chip, it is no longer necessary to accurately debug the commutation time point when the same motor matches different loads. The built-in program can add simple logic to realize advance judgment to ensure maximum motor efficiency. For example, a motor with an output power of 20W and a speed of 1500 rpm can drive various fan blade loads of about 5W to 15W without the need for secondary debugging, and can approach or reach the maximum efficiency point of 99%.

[0221] However, the six switching processes of traditional three-phase motors are implemented using a complex FOC (field orientation control) algorithm. Without secondary tuning to suit the load, the motor's efficiency will be significantly reduced. For example, if a traditional three-phase motor with a 20W output power and a 1500 rpm speed is driving a fan with a power output of approximately 5W to 15W, without secondary tuning, the efficiency may fall below 90% or even below 80% at a specific load of 15W. With secondary tuning, the maximum efficiency can reach over 95%. Furthermore, the maximum efficiency point of motors tuned by different personnel can vary.

[0222] Although some specific embodiments of the present disclosure have been described in detail through examples, those skilled in the art will understand that the above examples are for illustration only and are not intended to limit the scope of the present disclosure. Those skilled in the art will understand that the above embodiments may be modified or some technical features may be replaced with equivalents without departing from the scope and spirit of the present disclosure. The scope of the present disclosure is defined by the appended claims.

Claims

1. A brushless motor, characterized in that: include: At least one stator core (1), the stator core (1) comprising a plurality of tooth groups (11) arranged at intervals along its circumference, the total number of the tooth groups (11) being Z; A rotor (2) rotatable relative to the stator core (1), the rotor (2) comprising a magnetic ring (21) having a pole number P, where P is an even number; and At least two-phase conductors (3) are wound around the tooth group (11) to form coils (31) on the tooth group (11); the total number of phases of the conductors (3) is X, and each phase of the conductors (3) has an independent first end and a second end; for the conductors (3) of the same phase, the number of tooth groups (11) between the coils (31) on two adjacent tooth groups (11) is X-1, and the winding directions of the coils (31) on two adjacent tooth groups (11) along the circumference of the tooth group (11) are opposite; Among them, Z=P*X.

2. The brushless motor according to claim 1, characterized in that: The tooth set (11) comprises a single tooth (11'), the conductive wire (3) being wound around the tooth (11') to form a coil (31) on the tooth (11'); and / or The tooth group (11) comprises at least two teeth (11'), the at least two teeth (11') are arranged at intervals along the circumference of the stator core (1), and the conductive wire (3) is wound around the at least two teeth (11') to form a coil (31) on the at least two teeth (11').

3. The brushless motor according to claim 1, characterized in that: The conductor (3) of each phase is configured to pass an independent driving signal.

4. The brushless motor according to claim 1, characterized in that: In the radial direction of the stator core (1), the winding direction of each coil (31) formed by at least two phases of the conductive wires (3) is consistent.

5. The brushless motor according to claim 4, characterized in that: The starting winding position of each coil (31) formed by at least two phases of the conductive wires (3) is located on a side away from the rotor (2).

6. The brushless motor according to claim 1, characterized in that: In the radial direction of the stator core (1), the first end and the second end of the conductive wire (3) of at least two phases are led out from the same side of the tooth group (11).

7. The brushless motor according to claim 1, characterized in that: In the circumferential direction of the stator core (1), all the first ends and the second ends are led out from a plurality of adjacent tooth groups (11).

8. The brushless motor according to claim 7, characterized in that: in, The winding directions of the coils (31) of at least two phases of the conductive wires (3) located at the same sequence number from the first end along the circumference of the tooth group (11) are consistent; or The winding directions of the coils (31) of at least one group of adjacent two phases of the conducting wires (3) located at the same sequence number from the first end are opposite along the circumference of the tooth group (11).

9. The brushless motor according to claim 1, characterized in that: At least two phases of the conductive wires (3) are wound in sequence from the 1st phase to the Xth phase along the circumferential direction of the stator core (1); The conductor (3) through which the driving signal is passed comprises an i-th phase conductor (3) and a k-th phase conductor (2), and the phase difference between the driving signal of the i-th phase conductor (3) and the driving signal of the k-th phase conductor (2) is Among them, 1≤i<k≤X; In the same stator core (1), the tooth group (11) of the x-phase conductor (3) and the adjacent tooth groups (11) on both sides have a gap at the closest position, and the gap has a center position in the circumferential direction of the stator core (1); in all the gaps formed by the Z tooth groups (11), the central angle corresponding to the arc between the center position of the x-phase conductor (3) and the adjacent center position in the circumferential direction of the stator core (1) is β X , and β X The corresponding sector includes at least part of the tooth set (11) of the xth phase conductor (3).

10. The brushless motor according to any one of claims 1 to 9, characterized in that: The stator cores (1) are stacked in a plurality in the axial direction, and each of the stator cores (1) includes at least one phase of the conductor (3). In the circumferential direction of the stator core (1), the tooth groups (11) of the plurality of stator cores (1) are staggered.

11. The brushless motor according to any one of claims 1 to 9, characterized in that: Within the entire target speed range of the rotor (2), the strength of the driving signals passed through the conductors (3) of all phases is consistent.

12. The brushless motor according to any one of claims 1 to 9, characterized in that: When the target torque of the rotor (2) is higher than the first preset torque, the strength of the driving signal passed through each phase conductor (3) is consistent; When the target torque of the rotor (2) is not higher than the first preset torque, the drive signals passed through the conductors (3) of some phases have a preset strength, and the drive signals passed through the conductors (3) of the remaining phases are lower than the preset strength or are not driven.

13. The brushless motor according to any one of claims 1 to 9, characterized in that: The brushless motor has a first working mode. In the first working mode, the conductor (3) of each phase is energized throughout the entire period, and the driving signals between the conductors (3) of adjacent phases have a phase difference.

14. The brushless motor according to any one of claims 1 to 9, characterized in that: The brushless motor has a second working mode. In the second working mode, the conductor (3) of each phase is intermittently energized, and the driving signals between the conductors (3) of adjacent phases have a phase difference.

15. The brushless motor according to any one of claims 1 to 9, characterized in that: The magnetic ring (21) is sleeved outside the stator core (1).

16. The brushless motor according to any one of claims 1 to 9, characterized in that: The stator core (1) is annular and is sleeved outside the magnetic ring (21).

17. The brushless motor according to any one of claims 1 to 9, characterized in that: The stator core (1) and the magnetic ring (21) are arranged to overlap in the axial direction, and the magnetic ring (21) at least partially covers the coil (31) in the radial direction of the stator core (1).

18. The brushless motor according to claim 17, characterized in that: The stator core (1) is provided with the magnetic ring (21) on both sides along the axial direction; and / or The stator core (1) is provided on both sides of the magnetic ring (21) along the axial direction.

19. A device, characterized in that It comprises the brushless motor as claimed in any one of claims 1 to 18.

20. A method for manufacturing a brushless motor according to any one of claims 1 to 18, characterized in that: include: Wire supplying steps: providing a wire (3); Winding step: winding the conductive wire (3) on the tooth group (11) in different phase sequences until the coil (31) is formed on each tooth group (11); among all the coils (31) on the conductive wire (3) in the same corresponding direction, the number of tooth groups (11) between the coils (31) on two adjacent tooth groups (11) is X-1, and the winding directions of the coils (31) on two adjacent tooth groups (11) along the circumference of the tooth group (11) are opposite; The wire breaking step is to disconnect the wire (3) at the connection point of adjacent phase sequences, so that the total number of phases of the wire (3) is X, and each phase wire (3) has an independent first end and a second end.

Images