CN114337172A - Axial flux type PCB winding permanent magnet synchronous motor and stator thereof - Google Patents
Axial flux type PCB winding permanent magnet synchronous motor and stator thereof Download PDFInfo
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- CN114337172A CN114337172A CN202011069429.8A CN202011069429A CN114337172A CN 114337172 A CN114337172 A CN 114337172A CN 202011069429 A CN202011069429 A CN 202011069429A CN 114337172 A CN114337172 A CN 114337172A
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Abstract
The invention relates to an axial flux permanent magnet synchronous machine (100, 100') comprising a stator (110) and a rotor (120) arranged opposite the stator (110) in the axial direction, wherein the stator (110) comprises a single disc-shaped stator winding (111) configured as a printed circuit board (112), wherein the stator winding (111) comprises at least one set of coils (115) formed by lines in the printed circuit board (112), the stator (110) further comprising at least one stator core (113) attached to the stator winding (111), the stator core (113) being positioned such that it is at least partially surrounded by the coils (115) as seen in the axial direction. The invention also relates to a stator for such an electrical machine.
Description
Technical Field
The invention relates to an axial flux type permanent magnet synchronous motor, in particular to an axial flux type PCB winding permanent magnet synchronous motor. The invention also relates to a stator for an electrical machine.
Background
Conventional printed armature windings for printed circuit winding machines (printed circuit winding motors), while already enabling complex winding structures and precise coil positioning relative to conventional coil-type windings, are limited in application due to their large volume (especially thickness) and their inability to be easily integrated with power electronics and controllers.
To overcome these technical drawbacks, Printed Circuit Board (PCB) windings manufactured using modern PCB (printed Circuit board) technology have been proposed, wherein axial flux machines with PCB windings are a promising solution for a variety of applications. Such a motor can achieve a very small length/diameter ratio due to the very small thickness of the PCB winding, and thus can be advantageously applied to various applications having high requirements for installation space, such as hard disk drives, drones, home appliance products, and the like.
According to the prior art, the current PCB winding axial flux motor mainly adopts a coreless stator structure, that is, the stator only has a PCB winding without any iron core. Such coreless structures, while useful for weight reduction and eliminating cogging, have difficulty achieving high torque densities and thus have limited applications for electric machines.
To this end, a PCB-wound axial-flux electric machine 200 with a stator core is proposed, as shown in fig. 5. The motor 200 includes a stator and a rotor 220, wherein the rotor 220 is composed of a rotor core 221 and a permanent magnet 222, a bearing 260 is provided between the stator and the motor shaft 230 and includes a PCB winding 211 and a stator core 217 axially stacked with the PCB winding 211 as a separate additional layer. The drawbacks of this solution are: the stator core 217 significantly increases the axial length of the motor, thereby being disadvantageous to miniaturization of the motor.
Accordingly, it is desirable to provide an axial flux machine that is compact and has a high torque density.
Disclosure of Invention
The object of the present invention is achieved by providing an axial flux permanent magnet synchronous machine in which a planar core is applied on the same PCB board with a PCB winding structure. In particular, a permanent magnet synchronous machine comprises a stator and a rotor arranged opposite the stator in the axial direction, wherein the stator comprises a single disc-shaped stator winding configured as a printed circuit board, wherein the stator winding comprises at least one set of coils formed by lines in the printed circuit board, the stator further comprising at least one stator core attached to the stator winding, the stator core being positioned such that-seen in the axial direction-it is at least partially surrounded by the coils.
It should be noted here that the expression "at least partially enclosed, viewed in the axial direction", is to be understood in this context to have the following meaning in both respects. In a first aspect, the projected pattern of the stator core is at least partially embraced by the projected pattern of the coil if projected along a plane perpendicular to the axial direction. In the second aspect, the expression does not have a limiting meaning as to whether the axial extensions of the stator core and the coil overlap, i.e. both may at least partially overlap with respect to each other in the axial direction or may be completely offset with respect to each other.
According to an alternative embodiment, the stator core is constructed as a flat planar body.
According to an alternative embodiment, the planar body is prefabricated and then assembled to the stator winding, either finished or not finished; and/or
According to an alternative embodiment, the planar body is formed directly in and/or on the stator winding during the manufacturing process of the stator winding.
According to an alternative embodiment, the planar body is assembled to the stator winding by means of insertion or mounting.
According to an alternative embodiment, the stator winding is provided with at least one hole at least partially surrounded by the coil, each hole receiving a respective one of the stator cores.
According to an alternative embodiment, the holes are configured as through-holes through the stator winding or as semi-through-holes.
According to an alternative embodiment, a plurality of stator cores are distributed with a spacing in and/or on the stator winding.
According to an alternative embodiment, the stator winding comprises one or more wiring layers, wherein the stator winding comprises a plurality of groups of coils in the same wiring layer, each group of coils being respectively assigned to a respective one or more stator cores.
According to an alternative embodiment, the permanent magnet synchronous machine comprises one or more rotors and/or one or more stators, wherein the rotors and the stators alternate with each other in the axial direction.
According to an alternative embodiment, the stator winding is formed by a single-layer printed circuit board wired on one or both sides or by a multilayer printed circuit board made of a plurality of single-or double-sided printed wiring substrates by lamination.
According to an alternative embodiment, the permanent magnet synchronous machine further comprises an additional stator core layer, which is axially stacked with the stator windings.
The object of the invention is also achieved by a stator for an electrical machine, in particular an axial flux permanent magnet synchronous machine, comprising a single disc-shaped stator winding configured as a printed circuit board, wherein the stator winding comprises at least one set of coils formed by lines in said printed circuit board, the stator further comprising at least one stator core attached to the stator winding, said stator core being positioned so as to be at least partially surrounded by the coils, seen in a direction perpendicular to the plane of the board of the printed circuit board.
By the invention, the following effects are realized:
effectively increasing the torque density without significantly increasing the axial length of the machine, thereby making the machine more efficient and compact;
the manufacturing process of the stator is simplified by eliminating the traditional process steps such as winding insertion, wire-to-wire head welding, etc.;
complex winding structures and accurate coil positioning are flexibly achieved with mature PCB and PCBA technology;
the parameters of the stator can be calculated and controlled more precisely by means of the PCB windings, thus facilitating optimization of the motor design;
shortening the axial length of the motor by means of a smaller PCB winding thickness, thereby adapting the motor to scenarios with strict requirements on installation space;
mature PCB and PCBA technology offers more cost savings opportunities, especially for mass production; and
easy integration with power electronics and controllers.
Further advantages and advantageous embodiments of the inventive subject matter are apparent from the description, the drawings and the claims.
Drawings
Further features and advantages of the present invention will be further elucidated by the following detailed description of an embodiment thereof, with reference to the accompanying drawings. The attached drawings are as follows:
fig. 1 shows an exploded view of an axial flux permanent magnet synchronous machine 100 according to an exemplary embodiment of the present invention;
fig. 2 shows a cut-away view of an axial flux permanent magnet synchronous machine 100' according to another exemplary embodiment of the invention in an assembled state;
fig. 3 illustrates a perspective view of a stator 110 for electric machines 100 and 100' according to an exemplary embodiment of the present invention;
fig. 4 illustrates a plan view of the stator 110 illustrated in fig. 3; and
fig. 5 illustrates a partially exploded view of axial-flux motor 200, according to the prior art.
Detailed Description
In order to make the technical problems, technical solutions and advantageous effects of the present invention more apparent, the present invention will be described in further detail with reference to the accompanying drawings and exemplary embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and do not limit the scope of the invention. In the drawings, the same or similar reference numerals refer to the same or equivalent parts.
Fig. 1 shows an exploded view of an axial flux permanent magnet synchronous machine 100 according to an exemplary embodiment of the present invention. As shown in fig. 1, the motor 100 includes a stator 110, a rotor 120 disposed opposite to the stator 110 in an axial direction, a motor shaft 130 rotatably coupled to the rotor 120, and a housing 140 for enclosing the stator 110 and the rotor 120.
According to an exemplary embodiment, the rotor 120 includes a rotor base 121 in the shape of a disk and at least one permanent magnet 122 carried on the rotor base 121 on a side of the rotor base 121 facing the stator 110. The rotor base 121 may be configured as a rotor core and opened at the center thereof with a rotor center hole 123 (see fig. 2) through which the motor shaft 130 passes. The permanent magnet 122 has a flat planar shape, for example, a fan shape. In one example, a plurality of permanent magnets 122 are distributed on the rotor base 121 at angular intervals along a ring that surrounds the rotor central bore 123.
The shape, size, number, and arrangement of the permanent magnets 122 may be designed in correlation with wiring patterns of the stator windings 111 (explained in detail below) to optimize electromagnetic characteristics of the electric machine 100.
According to an exemplary embodiment, the stator 110 includes a single disc-shaped stator winding 111, wherein the stator winding 111 is fabricated as one Printed Circuit Board (PCB) 112. Thus, in the context of this document, the stator winding 111 is also referred to as a PCB stator winding. The stator winding 111 includes at least one set of coils 115 configured to generate a magnetic field by passing a current, the coils 115 being formed from wires or traces in the printed circuit board 112. Further, the stator winding 111 is opened at the center thereof with a stator center hole 116 through which the motor shaft 130 passes (see fig. 3).
Further, the stator 110 further comprises at least one stator core 113 attached to the printed circuit board 112, each stator core 113 being positioned such that it is at least partially surrounded by a coil 115, seen in axial direction. By installing stator core 113, the air gap flux density can be increased, thereby improving the torque density of the motor.
According to an exemplary embodiment, the stator winding 111 is provided with at least one aperture 114 (see fig. 4) at least partially surrounded by a coil 115, each aperture 114 receiving a respective one of the stator cores 113. Optionally, the hole 114 is configured as a through-hole or as a semi-through-hole through the printed circuit board 112. In this way, the torque density of the motor can be increased with little increase in the axial length of the motor.
The stator core 113 is, for example, configured as a flat planar body with a narrow surface area, which can be prefabricated and then assembled to the stator winding 111, which may or may not be completely produced. For example, the stator core 113 may be integrated with the stator windings 111 in an assembly step of the electric machine or may be assembled to the printed circuit board 112 with other possible electronics after PCB bare board fabrication is completed during a PCBA process flow for fabricating the stator windings 111.
Additionally, the stator core 113 is fixed within the bore 114 in a manner that is limited in movement relative to the stator windings 111. For this purpose, stator core 113 can be locked in hole 114 in a form-locking, force-locking and/or material-bonding (e.g., adhesive bonding) manner in order to limit the mobility of stator core 113 relative to stator winding 111.
In another exemplary embodiment, the stator core 113 may be attached to the stator winding 111. The stator core 113 to be mounted does not need to be provided with the holes 114 in the stator winding 111.
In yet another exemplary embodiment, the stator core 113 may be formed directly in and/or on the printed circuit board 112 using a suitable process during the manufacture of the printed circuit board 112, such as in-situ molding using a composite soft magnetic material. This means that the stator core 113 does not need to be manufactured in advance.
In particular, the stator 100 includes a plurality of stator cores 113 having a circumferential and/or radial spacing distribution in and/or on the printed circuit board 112. These stator cores 113 may be mounted by one of all three methods of insertion, mounting, and direct forming, or may be mounted by any two or three of these methods, that is, by being partially inserted or mounted, partially mounted, or directly formed.
Alternatively, the electric machine 100 may additionally include an additional stator core layer 117 for the stator 110, as shown in fig. 2. The stator core layer 117 is stacked axially as a separate layer with the PCB stator winding 111 to improve the air gap flux density of the machine. Illustratively, the stator core layer 117 is annular. The solution can be adapted to the circumstances where the installation space allows.
Furthermore, the printed circuit board 112 as stator winding 111 has at least one, in particular two or more, for example up to eight or ten, wiring layers, each of which contains a line as coil 115.
In the case where one wiring layer is provided, the printed circuit board 112 may be configured as a single-layer printed circuit board wired on one side. At this time, the wiring layer may be located on a side of the stator winding 111 facing the rotor 120.
In the case where two wiring layers are provided, the printed circuit board 112 may be configured as a single-layer printed circuit board with double-sided wiring. In the case of more than two wiring layers, the printed circuit board 112 can be configured as a multilayer printed circuit board, i.e. as two or more than two printed circuit substrates, which can each be selectively wired on one side, on both sides or even as empty boards. Illustratively, the center printed wiring substrate in the printed circuit board 112 is double-sided wired, while the remaining printed wiring substrates are single-sided wired.
In the case of a multilayer printed circuit board, a plurality of printed wiring substrates are laminated together during PCB manufacture, especially before outer layer printed wiring, to form one integral PCB winding 111. For example, the printed wiring substrates can be bonded together by means of an adhesive sheet during lamination.
According to an exemplary embodiment, the stator winding 111 comprises a plurality of groups of coils 115 within the same wiring layer, wherein each group of coils 115 is respectively assigned to a respective one or more stator cores 133. The arrangement position of each stator core 133 is set based on the electromagnetic characteristics. Alternatively, at least one stator core 113 may be positioned at the center of the corresponding coil 115, respectively. Additionally or alternatively, at least one stator core 113 may be positioned off-center from the center of the respective coil 115 for electromagnetic optimization. Additionally or alternatively, the coils 115 are distributed in the printed circuit board 112, in particular in an annular manner around the stator central bore 116, with angular intervals, and correspondingly the stator cores 113 are also distributed in an annular manner with angular intervals. Illustratively, each set of coils 115 is formed from a conductor line extending along a two-dimensional spiral, as best shown in fig. 4. In this case, the stator core 113 and the hole 114 (if any) for receiving the stator core 113 may be arranged at the center of each two-dimensional spiral or with a certain deviation from the center.
According to an exemplary embodiment, each wiring layer of the stator windings 111 may have the same or different conductor patterns or winding patterns. Alternatively, the stator windings 111 may have conductor patterns that are mirror images or slightly different from each other in adjacent wiring layers.
Optionally, the printed wiring substrates in the stator windings 111 are oriented such that the conductor patterns in the printed wiring substrates are axially aligned or at least partially misaligned with each other.
Here, the coil wiring method and the core position of the stator winding are not particularly limited in the present invention. Rather, the motor of the present invention may use any suitable coil routing and core location.
According to an exemplary embodiment, the hole 114 for receiving the stator core 113 may be machined after or during the manufacture of the printed circuit board 112. The processes used in the prior art to form PCB vias may be adapted for the fabrication of the holes 114.
In the illustrated exemplary embodiment, the electric machine 100 includes a single rotor 120 and a single stator 110. Alternatively, the electric machine may also comprise two or more rotors 120 and/or two or more stators 110. In this case, the rotors 120 and the stators 110 may be alternately arranged one by one with each other in the axial direction. That is, one stator 110 is always disposed between two rotors 120 that are consecutive in the axial direction, and one rotor 120 is always disposed between two stators 110 that are consecutive in the axial direction. It should be noted here that, in the case of a plurality of stators 110, each stator 110 still comprises only a single disc-shaped PCB stator winding 111.
In one example, the stator core 113 is made of a soft magnetic material, such as silicon steel, Soft Magnetic Composite (SMC), or the like.
In one example, a PCB stator winding 111 with eight wiring levels has an axial length of about 2.0mm, and a PCB stator winding 111 with ten wiring levels has an axial length of about 2.2 mm.
In an example, the axial length of the PCB stator winding 111 is 2.2mm or less, such as 2.0mm or less, in particular 1.5mm or less.
According to an exemplary embodiment, the motor shaft 130 may be configured as a stepped shaft. In the assembled state of the motor as shown in fig. 2, the motor shaft 130 extends through the stator center hole 116 and the rotor center hole 123 such that both ends thereof protrude outside the housing 140, as shown in fig. 2.
According to an exemplary embodiment, the housing 140 is comprised of a first housing portion 141 and a second housing portion 142 that are connected to each other. In the assembled state of the motor, the first and second housing parts 141, 142 abut against each other to enclose a space for accommodating the stator 110 and the rotor 120.
Although some embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the invention. The appended claims and their equivalents are intended to cover all such modifications, substitutions and changes as fall within the true scope and spirit of the invention.
Claims (11)
1. An axial flux permanent magnet synchronous machine (100, 100') comprising a stator (110) and a rotor (120) arranged opposite the stator (110) in an axial direction, wherein the stator (110) comprises a single disc-shaped stator winding (111) configured as a printed circuit board (112), wherein the stator winding (111) comprises at least one set of coils (115) formed by lines in the printed circuit board (112), the stator (110) further comprising at least one stator core (113) attached to the stator winding (111), the stator core (113) being positioned such that it is at least partially surrounded by the coils (115) as seen in the axial direction.
2. The permanent magnet synchronous machine (100, 100') according to claim 1,
the stator core (113) is configured as a flat planar body.
3. The permanent magnet synchronous machine (100, 100') according to claim 2,
the planar body is prefabricated and then assembled to a stator winding (111) that is either finished or not finished; and/or
The planar body is formed directly in and/or on the stator winding (111) during the production of the stator winding (111).
4. The permanent magnet synchronous machine (100, 100') according to claim 3,
the planar body is assembled to the stator winding (111) in an insertion or mounting manner.
5. The permanent magnet synchronous machine (100, 100') according to claim 4,
the stator winding (111) is provided with at least one hole (114) at least partially surrounded by a coil (115), each hole (114) receives a corresponding stator core (113), and the holes (114) are formed into through holes or semi-through holes penetrating through the stator winding (111).
6. The permanent magnet synchronous machine (100, 100') according to any one of the preceding claims,
the plurality of stator cores (113) are distributed in and/or on the stator winding (111) with a spacing.
7. The permanent magnet synchronous machine (100, 100') according to any one of the preceding claims,
the stator winding (111) comprises one or more wiring layers, wherein the stator winding comprises a plurality of groups of coils (115) in the same wiring layer, and each group of coils is respectively assigned to one or more corresponding stator cores.
8. The permanent magnet synchronous machine (100, 100') according to any one of the preceding claims,
the permanent magnet synchronous motor comprises one or more than one rotor (120) and/or one or more than one stator (110), wherein the rotor (120) and the stator (110) are arranged in an alternating manner one by one in the axial direction.
9. The permanent magnet synchronous machine (100, 100') according to any one of the preceding claims,
the stator winding (111) is formed by a single-layer printed circuit board with one or two-sided wiring or a multi-layer printed circuit board which is formed by laminating a plurality of printed circuit boards with one or two-sided wiring.
10. The permanent magnet synchronous machine (100, 100') according to any one of the preceding claims,
the permanent magnet synchronous machine further comprises an additional stator core layer (117) which is axially stacked with the stator winding (111).
11. A stator (110) for an electrical machine comprising a single disc-shaped stator winding (111) configured as a printed circuit board (112), wherein the stator winding (111) comprises at least one set of coils (115) formed by wires in the printed circuit board (112), the stator (110) further comprising at least one stator core (113) attached to the stator winding (111), the stator core (113) being positioned such that it is at least partially surrounded by the coils (115) seen in a direction perpendicular to a plate plane of the printed circuit board (112).
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202011069429.8A CN114337172A (en) | 2020-09-30 | 2020-09-30 | Axial flux type PCB winding permanent magnet synchronous motor and stator thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202011069429.8A CN114337172A (en) | 2020-09-30 | 2020-09-30 | Axial flux type PCB winding permanent magnet synchronous motor and stator thereof |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN114337172A true CN114337172A (en) | 2022-04-12 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202011069429.8A Pending CN114337172A (en) | 2020-09-30 | 2020-09-30 | Axial flux type PCB winding permanent magnet synchronous motor and stator thereof |
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| CN (1) | CN114337172A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116566153A (en) * | 2023-05-18 | 2023-08-08 | 中国农业大学 | Magnetic field modulation disc type PCB motor and application thereof |
-
2020
- 2020-09-30 CN CN202011069429.8A patent/CN114337172A/en active Pending
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116566153A (en) * | 2023-05-18 | 2023-08-08 | 中国农业大学 | Magnetic field modulation disc type PCB motor and application thereof |
| CN116566153B (en) * | 2023-05-18 | 2024-01-23 | 中国农业大学 | Magnetic field modulation disc type PCB motor and application thereof |
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