CN1434557A - 无刷直流电机 - Google Patents
无刷直流电机 Download PDFInfo
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Abstract
一种无刷直流电机包括外壳10,位于外壳中的一个定子13和一个转子11,定子上的线圈,用来感知转子相对于定子位置的传感器,以及根据传感器的输出来转换线圈中电流并使得转子相对于定子转动的电路。传感器和至少电路的一部分封装在外壳容器内的电绝缘和耐油材料中。
Description
技术领域
本发明涉及一种无刷直流电机,更具体地涉及并非专门与燃油泵一起使用的电机。
背景技术
常规的永磁体直流(PMDC)电机一般设计为相对比较便宜的包括换向器和电刷/叶片***的换向部分。在许多特殊应用方面,这些电刷类型的电机很重要,尤其是在低端的应用领域。
另一方面,从不同电压的各种汽车到专门的电力设备,对电子控制***的依赖性正在增加。同时,长寿命,高效,可靠性强,低电磁干扰和噪声这些参数变得更加重要。
无刷直流(BLDC)电机技术能够满足这些要求。和电刷相关的问题得到消除。利用先进的金属氧化物半导体场效应晶体管(MOSFET)和表面装配技术,使得产生较低的电压降落(由于散热片的减少),较小的体积和价格成下降趋势。
发明内容
根据本发明的第一方面,这种无刷直流电机包括一个外壳,位于外壳中的一个定子和一个转子,在所述定子或转子上的线圈,用来感知转子相对于定子位置的传感器,以及根据传感器的输出转换线圈中电流并使得转子相对于定子转动的电路,传感器和至少电路的一部分封装在外壳容器的电绝缘材料中。
本发明第二方面的优选和/或可选特征在权利要求2~8中列出。
根据本发明的第二方面,这种无刷直流电机包括了一个缠绕定子和一个永磁体转子,所述转子具有一个叠片铁芯并且由在浇铸后进行磁化的可磁化材料浇铸而成。
本发明第二方面的优选或者可选特征在权利要求9~14中列出。
本发明两方面的优选或者可选特征在权利要求15~17中列出。
附图说明
参照说明书附图通过具体实施例,本发明将会得到进一步描述:
图1是本发明所述的无刷直流电机的一种实施例的透视图,
图2是图1所示电机的剖视图,
图3是用来容纳图1和图2所示电机电子线路的器的分解透视图,
图4是图3中所示的容器的透视图,它安装在定子上并且容纳了电子线路,
图5是图3所示的容器下方透视图,
图6是电机的前绝缘体的透视图,
图7是电机的转子的透视图,
图8是图7所示转子的部分剖视图,
图9是电机转子和定子的叠片结构的平面图,
图10是改进的转子叠片结构第二实施例的平面图,
图11是另一种改进的转子叠片结构的平面图,
图12是另一种定子的部分透视图,
图13是图11所示增加了磁通部件的定子的透视图。
具体实施方式
参照附图,此无刷直流电机包括一个深拉拔的外壳10,带有一个轴12的转子11,此轴在从外壳10的闭合端凸出部分具有一个平面12a,一个包围着转子11的缠绕定子13,一个闭合外壳10的端盖14,以及一个位于外壳10中用来容纳传感器和电路的容器16。缠绕定子13包括被定子叠片结构30缠绕的定子线圈19。
这种电机具有和传统永磁体直流电机相似的外观,都具有包括换向器和电刷/叶片***的换向部分。这种电机特别适用于燃油泵电机,但也具有其他的用途。
参照图3到5,容器16包括一个圆柱状的碗状物17,它具有一个从碗状物底部凸出的整体的套筒18。容器一般由树脂(POM)制成,它容纳了传感器,传感器一般是霍耳效应传感器,用来感知转子11相对于定子13的位置,容器也容纳了电子线路,它安装在和凸出的套筒18相配合安装的环形印刷电路板20上。理想情况下,霍耳效应传感器水平安置于印刷电路板20上。由于更加易于安装并且在完全封装后能够更加可靠的防油和防震,这样和传统的“直立的”霍耳效应传感器相比具有优势。同时,它也减少了传感器和永磁体转子平的顶部之间的距离。电路通过已知方式相应于传感器的输出来转换定子线圈中的电流,以使转子相对于定子转动。传感器和电路封装在电绝缘材料中,一般是环氧树脂,它充满或者基本上充满于容器16。套筒18是定尺度的以使得转子轴12可以穿过并且使得来自燃油泵的燃油流过。
传感器和大部分电子部件,包括所有的导电部分都完全封装。只有例如电子端子和大的电容器这些部件不必完全封装。
如图5所示,碗状物17底部下面具有四个绝缘位移连接器21用来直接连接到定子13的线圈。容器16和它的附属物可以预装“***”电机中。
由于通过套筒18的燃油的冷却作用,封装材料的导热性能并不是很重要。
图6详细地示出了安装在定子上的前部绝缘体22,它具有相同数量的槽23(本例中为四个)用来容纳定子线圈和容器16上的绝缘位移连接器21。
代替在印刷电路板上安装传感器和电子电路的是,容器16的内部底表面可以印制成导电模板。这可以采取利用热压印机生成热压金属箔的方式。所有的电部件可以自动安装在碗状物的内表面随后进行封装。这种技术的另一个好处就是进一步减少霍耳传感器和转子磁极的平项部之间的距离,使得探测位置时磁场力增加。
电机也具有一个后部的绝缘体24,它与前部绝缘体22相似但并不完全相同。
端盖14这样连接于外壳10如通过在例如两个位置处卷曲外壳10的边缘到端盖上。这个端盖14支撑或限定了一个转子轴12的轴承,并且也包括了用户燃油泵所需要的整体特征。端盖14提供了终端26用来连接外部供电。
在电机的另一端安置有套筒15。套筒15一般由聚苯撑硫(PPS)制成。这种材料具有高的耐热空间稳定性,低的延伸性能以及特别好的抵抗各种腐蚀性燃油的性能。套筒15支撑或者限定了一个转子轴12的轴承,并且该套筒也用来通过压配到燃油泵外壳上的小孔中从而连接到用户的燃油泵上。通常,套筒15是泵外壳的一部分。现在它是电机的一部分。当它为了竞争目的用来支撑或者限定一个转子轴12的轴承以及充当泵外壳的连接/对准部件时,这种设计就更有优势了,并且它还可以使得电机供应给用户前做完全的测试。
和传统的换向器电机相比这种无刷直流电机使得半径和轴向尺寸的减少成为可能。
参照附图7到11,转子包括转子轴12和用材料33浇铸而成并在浇铸后进行磁化的叠片铁芯27。
叠片铁芯27包括许多转子叠片结构29。如图9所示,这些叠片结构通过薄片金属冲压而成并且可以在冲压定子叠片结构30的同时冲压而成,以节省单独生产一个铁芯的成本。转子叠片29具有三个等角度布置的,径向朝内伸展的槽31和一个中心孔32,用来在转子轴12上安装叠片。一叠叠片30都用可磁化材料33浇铸而成,一般为热塑性结合的NdFeB化合物,并且这个(各向同性的)材料33在浇铸后磁化(如图7所示)。整体环34也浇铸而成,它可以象一个编码圆盘一样被装载用来在轴向产生较高的磁场力(对于霍耳传感器是必要的)。
这种方式形成的转子不需要任何粘结并且易于装配,同时也不需要调整平衡。浇铸材料33也填充在槽31中。
图10给出了具有六个孔35的另一种转子叠片。这些孔35等角度布置,并且其中有三个孔比其他的大一些。这减少了转子铁芯27的重量,然而为了避免燃油泵转子冲力的损失(例如由于转子在液体里湍流而产生的损失),端部的叠片最好没有这样的孔35。
图11给出了进一步的不具有槽31的转子叠片但是它具有不均匀的滚花外表面和六个相同尺寸的孔35’。
图9所示的定子叠片30与转子叠片同时冲压而成,并且包括外环36,四个等角度布置沿径向向内伸展的磁极37,磁极37缠绕(图中未示出)了线圈,有四个磁通部件布置在每两个磁极37之间。因为磁极37和磁通部件38之间的小间隙,一叠这样的叠片比较难于缠绕。同时,随后会***到外环上的环绕磁极外部缠绕线圈不推荐使用到小尺寸电机上去。
如图12和13所示的本发明的一方面,一种可选择的定子13’,具有
外环36’,许多成角度布置从外环36’沿径向向内伸展的磁极37’,以及许多位于磁极37’之间的磁通部件38’。磁通部件38’与环36’和磁极37’相分离,并且可以移动进入由磁极37’缠绕线圈之后的外环36’限定的槽39中。这样简化了缠绕过程并且使得磁通部件38成形最佳。
环36’和磁极37’是整体制成的并且可以由能够保证安装在一起的冲压叠片制成,这些叠片通过例如激光焊,成套冲压或者更多可选方式用可铸造的软磁烧结材料制成整体结构。
上述的实施方式仅仅通过具体实施例进行了描述,对本领域技术人员而言其不同的修改均是显而易见的,而不超出本发明附加权利要求所限定的保护范围。例如,转子可以环绕定子,这种情况一般常用作风机马达或者蓄电驱动器。
Claims (18)
1.一种无刷直流电机包括一个外壳(10),位于外壳中的一个定子(13)和一个转子(11),定子上的线圈,用来感知转子相对于定子位置的传感器,以及根据传感器的输出来转换线圈中电流并使得转子相对于定子转动的电路,其特征在于传感器和至少电路的一部分封装在外壳内容器的电绝缘和耐油材料中。
2.如权利要求1所述的电机,其特征在于所述传感器是霍耳效应传感器,该传感器水平位于或者邻近于容器(16)最接近转子(11)的端部。
3.如权利要求1所述的电机,其特征在于电路的所有导电部分封装在电绝缘和耐油的材料里。
4.如权利要求1所述的电机,其特征在于容器(16)具有一个内套筒(18),转子的轴(12)穿过它,并且来自燃油泵的燃油可以流过它。
5.如权利要求1所述的电机,其特征在于传感器和电路安装在容器(16)的印刷电路板(20)上。
6.如权利要求1所述的电机,其特征在于传感器和电路的电子部件通过印制在容器内表面的导电模板电连接。
7.如权利要求1所述的电机,其特征在于容器(16)具有外部的绝缘位移连接件(21)用来直接连接到线圈上。
8.如权利要求1所述的电机,其特征在于容器(16)和它的部件是预装的。
9.一种无刷直流电机包括缠绕定子(13)和永磁体转子(11),其特征在于转子(11)具有叠片铁芯(27)并且由浇铸后进行磁化的材料(33)铸造而成。
10.如权利要求9所述的电机,其特征在于转子铁芯具有许多成角度布置的槽(31),它从外表面向内伸展并且槽内填满所述的材料(33)。
11.如权利要求9所述的电机,其特征在于至少一些叠片(29)具有许多间隔的孔(35)。
12.如权利要求9所述的电机,其特征在于叠片(29)的外周表面是不平坦的。
13.如权利要求12所述的电机,其特征在于叠片(29)的外周表面是滚花的。
14.如权利要求9所述的电机,其特征在于进一步包括用来感知转子相对于定子位置的传感器,以及根据传感器中输出来转换定子线圈中电流并使得转子相对于定子转动的电路。
15.如权利要求1到14任一所述的电机,其特征在于定子(13)围绕着转子(11)并且具有一个外环(36),许多成角度布置从外环向内伸展的磁极(37)和许多位于磁极之间的磁通部件(38),磁通部件在将线圈安装到磁极后被***。
16.如权利要求15所述的电机,其特征在于外环(36)在其内表面限定了许多槽(39),用来在每对相邻的缠绕磁极(37’)之间可滑动地安装磁通部件(38’)。
17.如权利要求15所述的电机,其特征在于进一步包括在电机一端的套筒(15),用来支撑或者限定一个转子的轴承以及用来连接到一燃油泵上。
18.如权利要求1到14任一所述的电机,其特征在于进一步包括在电机一端的套筒(15),用来支撑或者限定一个转子的轴承以及用来连接到燃油泵上。
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GB0130602.6 | 2001-12-21 | ||
GBGB0130602.6A GB0130602D0 (en) | 2001-12-21 | 2001-12-21 | Brushless D.C. motor |
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CNA2007100886807A Division CN101026328A (zh) | 2001-12-21 | 2002-12-21 | 无刷直流电机 |
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CNB021400091A Expired - Fee Related CN100342626C (zh) | 2001-12-21 | 2002-12-21 | 无刷直流电机 |
CNB021611017A Expired - Fee Related CN100454721C (zh) | 2001-12-21 | 2002-12-21 | 电动机以及其与燃油泵结合在一起的组件 |
CNA2007100886807A Pending CN101026328A (zh) | 2001-12-21 | 2002-12-21 | 无刷直流电机 |
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CNB021611017A Expired - Fee Related CN100454721C (zh) | 2001-12-21 | 2002-12-21 | 电动机以及其与燃油泵结合在一起的组件 |
CNA2007100886807A Pending CN101026328A (zh) | 2001-12-21 | 2002-12-21 | 无刷直流电机 |
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JP (3) | JP2003224948A (zh) |
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