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WO2015090211A1 - 定子盘及轴向磁通永磁动能装置 - Google Patents

定子盘及轴向磁通永磁动能装置 Download PDF

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Publication number
WO2015090211A1
WO2015090211A1 PCT/CN2014/094195 CN2014094195W WO2015090211A1 WO 2015090211 A1 WO2015090211 A1 WO 2015090211A1 CN 2014094195 W CN2014094195 W CN 2014094195W WO 2015090211 A1 WO2015090211 A1 WO 2015090211A1
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WO
WIPO (PCT)
Prior art keywords
substrate
winding
windings
stator
permanent magnet
Prior art date
Application number
PCT/CN2014/094195
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English (en)
French (fr)
Inventor
段建华
吴小青
阳小飞
周飞
赵巍
Original Assignee
湖北海山科技有限公司上海分公司
珠海市和鸿企业有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Application filed by 湖北海山科技有限公司上海分公司, 珠海市和鸿企业有限公司 filed Critical 湖北海山科技有限公司上海分公司
Priority to US15/106,459 priority Critical patent/US20160336824A1/en
Publication of WO2015090211A1 publication Critical patent/WO2015090211A1/zh

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/26—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/28—Layout of windings or of connections between windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K21/00—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets
    • H02K21/12—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets
    • H02K21/24—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos

Definitions

  • the invention relates to the technical field of electrical equipment, and in particular to a stator disc and an axial flux permanent magnet kinetic energy device.
  • a stator coreless magnetic flux disk permanent magnet (AFPM) motor according to the principle of electromagnetic induction, generates a magnetic field around the energized conductor, and a phase current flowing through the stator winding generates a rotating magnetic field (rotary magnetomotive force) in the motor.
  • the main pole of the rotor produced by the rotor of the permanent magnet is like a magnet.
  • the rotating magnetic field of the stator attracts the permanent magnet rotor and rotates in the direction of rotation of the rotating magnetic field, thereby achieving the purpose of motor operation.
  • the core loss is avoided, and the core loss is referred to as "iron consumption”, also called “core loss” and “excitation loss”, which means magnetic
  • iron consumption also called “core loss” and “excitation loss”
  • excitation loss which means magnetic
  • the power loss caused by the alternating or pulsating magnetic field in the material is expressed in the form of heat, which is divided into hysteresis loss and eddy current loss, so it is more efficient than conventional motors, and it also has small volume and weight. Light weight, high power density, excellent control performance, simple manufacturing and so on.
  • axial flux disk permanent magnet motors can achieve different power requirements through different numbers of stator discs and permanent magnet rotors. It has broad application prospects to flux disk permanent magnet motors.
  • the axial flux disk permanent magnet motor has a small air gap.
  • the stator disk of the axial flux disk permanent magnet motor is required to be thin and flat.
  • stator discs mainly include coil winding sub-disks and printed circuit board stator discs.
  • the present invention solves the technical problems in the prior art that in the axial flux disk permanent magnet motor or the generator, the stator disk is not flat, the wire diameter is small, the power is small, the processing is complicated, and the manufacturing cost is high.
  • the present invention provides a stator disk comprising: a substrate, a plurality of windings, at least one connecting conductor, and a current terminal conductor; the substrate having a shaft hole; the connecting conductor being formed in the substrate, the plurality of windings All or part of the independent, located on the substrate, the independent windings are connected in whole or in part by the connecting conductor; the current terminal connecting conductor is formed in the substrate, and the winding is connected to the phase current.
  • the winding includes: a first winding edge and a second winding edge, wherein the first winding edge and the second winding edge are arranged radially along the shaft hole.
  • windings are arranged radially around the shaft hole.
  • the plurality of windings are a plurality of independent coils.
  • the coil wire diameter is 0.25 to 1.5 mm, and the total number of turns per phase winding has 16 to 70 ⁇ .
  • the substrate is a single side, and the plurality of windings are respectively located on one side of the substrate.
  • the substrate is double-sided, and the plurality of windings are respectively located on both sides of the substrate.
  • the substrate includes: a first via hole penetrating the substrate connected to the connection conductor and a second via hole extending through the substrate connected to the current terminal connection conductor for connecting All or part of the winding on the substrate.
  • the substrate is two or more, and the plurality of substrates are arranged in a superposition.
  • the invention also provides an axial flux permanent magnet kinetic energy device, comprising: a plurality of multiple permanent magnetic poles The rotor and any of the stator discs described above.
  • the plurality of rotors are respectively disposed on both sides of the stator disc such that a direction of a permanent magnet magnetic field of the rotor is perpendicular to the stator disc surface.
  • the axial flux permanent magnet kinetic energy device has a power of 50 watts to 5000 watts.
  • the present invention provides a stator disk and an axial flux permanent magnet kinetic energy device.
  • the winding of the stator disk is a single independent coil, which does not require multiple coils to be continuously wound, has simple processing and high production efficiency.
  • the substrate for fixing the connection winding adopts a simple low-cost single-sided or double-sided design, and a plurality of single coils, components, and sockets connected to the controller are soldered and mounted on the substrate, and the installation process is simple.
  • the substrate is used to realize the connection and installation between the winding coils, and the installation and connection of other electronic components and connectors, thereby avoiding the overlap caused by the connecting wires between the winding coils, effectively reducing the thickness of the stator disc and ensuring the thickness of the stator disc.
  • the stator disk is flat; at the same time, increasing the wire diameter of the winding coil or increasing the number of substrates on which the plurality of windings are mounted can improve the power and power density of the motor and improve the efficiency of the motor.
  • FIG. 1 is a schematic structural view of a stator disk according to an embodiment of the present invention.
  • FIG. 2 is a schematic structural view of a winding according to an embodiment of the present invention.
  • FIG. 3 is a schematic structural view of a stator disk according to an embodiment of the present invention.
  • FIG. 5A is a schematic front view showing a structure suitable for a single-phase current stator disk according to an embodiment of the present invention
  • FIG. 5B is a schematic view showing the structure of a back surface suitable for a single-phase current stator disk according to an embodiment of the present invention.
  • FIG. 5C is a schematic structural diagram of a single-phase current single-sided stator disk according to an embodiment of the present invention.
  • FIG. 5D is a schematic structural view of a single-phase current single-sided stator disk according to another embodiment of the present invention.
  • 6A is a schematic view showing the front structure of a two-phase current stator disk according to another embodiment of the present invention.
  • FIG. 6B is a diagram showing the structure of the back surface suitable for a two-phase current stator disk according to another embodiment of the present invention. intention;
  • 6C is a schematic structural view of a single-phase stator disk suitable for two-phase current according to an embodiment of the present invention.
  • FIG. 7A is a schematic front view showing a structure suitable for a three-phase current stator disk according to another embodiment of the present invention.
  • FIG. 7B is a schematic view showing the structure of a back surface suitable for a three-phase current stator disk according to another embodiment of the present invention.
  • FIG. 7C is a schematic structural diagram of a single-sided stator disk suitable for three-phase current according to an embodiment of the present invention.
  • stator disk in the axial flux disk permanent magnet motor or the generator, there is a technical problem that the stator disk is not flat, the wire diameter is small, the power is small, the processing is complicated, and the manufacturing cost is high, and the present invention designs a kind of The stator disk uses a substrate to connect and fix the windings disposed on the substrate according to the requirements of the number of power and current phases, thereby realizing the connection between the winding coils, which is not only simple in process, low in manufacturing cost, and avoids In the conventional coil winding method, the overlap between the connecting wires and the coils effectively reduces the thickness of the stator disk and ensures the flatness of the stator disk.
  • the wire diameter of the winding coil can be increased and the winding of the winding coil can be increased in a limited area.
  • the number, or increase the number of substrates with multiple windings improve the power and power density of the motor and generator, avoiding the shortcomings of small diameter and low power of the printed circuit board stator disk.
  • FIG. 1 there is shown a schematic structural view of a stator disk according to an embodiment of the present invention.
  • the stator disk includes: a substrate 110, a plurality of windings 120, at least one connecting conductor 130, and a current terminal connecting conductor 140; the substrate 110 has a shaft hole 111; the connecting conductor 130 is formed in the In the substrate 110, the plurality of windings 120 are all or partially independent, and are located on the substrate 110. The independent windings 120 are connected in whole or in part through the connecting conductors 130. The current terminal connecting conductors 140 are formed in the substrate 110. In the substrate 110, the winding 120 is connected to a phase current.
  • the stator disc uses a substrate for fixing the winding, and realizes connection of all or part of the winding through the conductor disposed in the substrate, which is not only simple in process, low in cost, but also avoids overlapping of the windings, effectively reducing the thickness of the stator disc, and ensuring the thickness.
  • the stator disk is flat.
  • connection conductor is formed in the substrate.
  • the manner in which the connection conductor is formed in the substrate may be, but is not limited to, the following:
  • the connecting conductor is processed according to design requirements, it is fitted or arranged in the substrate;
  • the designed connecting conductor pattern is formed in the printed circuit board.
  • FIG. 2 a schematic structural view of a winding according to an embodiment of the present invention is shown.
  • the winding in the stator disk includes: a first winding edge 210 and a second winding edge 220, wherein the first winding edge 210 and the second winding edge 220 are along the axis of the shaft hole 111
  • the first winding edge and the second winding edge along the radial direction of the shaft hole in the embodiment of the present invention refer to an effective winding edge functioning in the stator disk.
  • the winding coil may be a fan shape or a winding.
  • FIG. 3 a schematic structural view of a stator disk according to an embodiment of the present invention is shown.
  • the windings are arranged radially around the shaft hole 111, which avoids overlapping of the windings while lifting the effective working area of the winding, so that the currents of the phases do not interfere with each other, avoid crossover, and further reduce
  • the thickness of the stator disk ensures the flatness of the stator disk.
  • the plurality of windings are a plurality of independent coils, which can be separately processed during the production process, which makes the processing easier, avoids the difficulty of winding the continuous coil in the prior art, and improves the difficulty.
  • the production efficiency guarantees the processing quality, and under the premise of ensuring the electrical characteristics, the mutual interference between the multi-phase currents is reduced, and the overlap of the windings is avoided, the thickness of the stator disc is effectively reduced, and the flatness of the stator disc is ensured.
  • the winding coil can be adjusted according to the power requirement, in the high power motor Equipped with the wire diameter of the winding coil, increasing the number of turns of the winding coil, thereby increasing the power and power density of the motor, improving the efficiency of the motor, and expanding its application range.
  • the coil wire diameter is 0.25 to 1.5 mm, and the total number of turns of each phase winding is 16 to 70 turns.
  • the substrate is a single side, and the plurality of windings are respectively located on one side of the substrate.
  • the substrate is double-sided, and the plurality of windings are respectively located on two sides of the substrate.
  • the substrate when the substrate is double-sided, the substrate includes: a first via connected to the connecting conductor and a second via connected to the current terminal connecting conductor, where the connection is located All or part of the windings on the substrate. Through the first and second via holes, all or part of the winding coils on both sides of the substrate are connected together, and the storage space of the substrate is fully utilized to increase the power density.
  • the substrate of the stator disk is two or more, and the plurality of substrates are arranged in a superposition.
  • more windings can be mounted on multiple substrates, and during operation, more power is output to meet the needs of a larger power motor configuration.
  • FIG. 4 an axial flux permanent magnet kinetic energy device according to an embodiment of the present invention is shown.
  • the axial flux permanent magnet kinetic energy device comprises: a plurality of rotors 410 having multiple permanent magnetic poles and any of the stator disks 420 as described in the above embodiments.
  • the structure of the stator disk is as described in the foregoing embodiment, and details are not described herein again.
  • the plurality of rotors are respectively disposed on both sides of the stator disc, such that a permanent magnetic pole magnetic field direction of the rotor is perpendicular to the stator disc surface, and the axial flux permanent magnet kinetic energy device is applied
  • the stator disk when the stator disk is energized, Lorentz force is generated to drive the rotor to rotate, so that the electric device works;
  • the axial flux permanent magnet kinetic energy device when the axial flux permanent magnet kinetic energy device is applied to the field of the power generating device, when the permanent magnet rotor rotates,
  • the rotating magnetic flux of the winding coils is coupled to induce an electromotive force in the winding coils.
  • the axial flux permanent magnet kinetic energy device has a power of 50 watts to 5000 watts.
  • the structural size of the prototype is determined according to the given conditions; the relevant parameters such as air gap, yoke thickness and pole arc coefficient are selected according to the engineering design requirements and electromagnetic analysis results; based on the static magnetic field Electromagnetic analysis acquires relevant magnetic density and magnetic flux values; the no-load back EMF is based on reducing the stator current, improving the efficiency of the motor, reducing the temperature rise of the motor and taking into account the ratio of the rated voltage within a certain reasonable range; Calculate the number of windings per phase and consider the number of winding coils Select, finalize the number of turns, and determine the back EMF; the wire diameter and the number of winding turns are determined by considering the electric density, electric load, heat load and slot full rate; the output power is determined according to the potential constant and the torque constant; The friction loss and the loss of the armature to the air friction are based on the empirical coefficient. The copper loss is calculated based on the current and the resistance; finally, the efficiency is obtained.
  • the relevant parameters such as air gap, yoke
  • the disk type coreless permanent magnet synchronous generator having the stator disk of the above embodiment adopts an intermediate stator structure, that is, the motor is composed of a double rotor and a single stator, and the armature winding is Radially distributed, the effective conductor is located on the front surface of the permanent magnet.
  • the permanent magnet is dragged by the prime mover to the synchronous speed, a rotational magnetic flux is formed in the air gap, which is interlinked with the armature winding, thereby A three-phase AC electromotive force is induced in the winding.
  • the armature winding of the generator is made of enamelled round copper wire, the bare wire diameter is 0.9mm, 6 windings per phase, the total number of turns per phase winding is 66 ⁇ ; a total of 18 coils, 2 sides distributed, 9 coils per side
  • the power of the generator using the stator disk of the above embodiment reached 5,000 watts and the rotational speed reached 3600 rpm/min.
  • Embodiment 1 is a diagrammatic representation of Embodiment 1:
  • FIG. 5A is a schematic diagram showing the installation of a single-phase current winding on a circuit board according to an embodiment of the present invention.
  • the stator disk suitable for single-phase current includes: a substrate 510.
  • the substrate 510 has a double-sided structure, and the windings are respectively disposed on the front and back sides thereof, and have shaft holes for inserting the rotating shaft, the first connecting conductor 521.
  • the second connecting conductor 522 and the third connecting conductor 523 are formed in the substrate 510.
  • the current input terminal connecting conductor 541 and the current output terminal connecting conductor 542 are formed in the substrate 510 for connecting a single-phase current.
  • the first connecting conductor 521, the second connecting conductor 522 and the third connecting conductor 523 are respectively connected with six through holes 551, 552, 553, 554, 555, 556 penetrating through the substrate, and the current terminal connecting conductors 541 and 542 are connected.
  • a circuit input terminal via 561 and a current output terminal via 562 are connected, respectively.
  • windings 531, 532, 533, 534 are respectively disposed on the front and back surfaces of the substrate 510.
  • the first winding 531 and the third winding 533 are disposed on the front surface of the substrate 510;
  • the second winding 532 and the fourth winding 534 are disposed on the reverse side of the substrate 510.
  • Each winding has two terminals and the connection between the windings is achieved by connecting conductors and vias.
  • the second connecting conductor 522 is connected to one end of the third winding 533 located on the front surface of the substrate 510 through the fourth via 554, and is connected to the third connecting conductor 523 through the fifth via 555 via the other end of the third winding 533.
  • the third connecting conductor 523 is further connected to one end of the fourth winding 534 located on the back surface of the substrate 510 via the sixth via 556, and the other end of the fourth winding 534 is connected to the current output terminal connecting conductor 542 through the current output terminal via 562. Connected in sequence to form a current loop.
  • the four windings may be simultaneously disposed on one side of the substrate, and the three connecting conductors are connected as shown in FIG. 5C, and details are not described herein again.
  • four windings may be simultaneously disposed on one side of the substrate, and one connecting conductor is connected as shown in FIG. 5D, and details are not described herein again.
  • the dotted line in the figure does not represent any meaning.
  • Embodiment 2 is a diagrammatic representation of Embodiment 1:
  • FIG. 6A and FIG. 6B a schematic diagram of the installation of a two-phase current winding on a circuit board according to an embodiment of the present invention is shown.
  • the stator disk suitable for the two-phase current comprises: a substrate 610.
  • the substrate 510 has a double-sided structure, and the eight windings are respectively disposed on the front and back sides thereof, and the shaft hole 611 has a shaft hole 611 for inserting the rotating shaft.
  • the connecting conductors 621, 622, 623, 624, 625, 626 are formed in the substrate 610; the six connecting conductors are respectively connected with 12 through holes 6501 to 6512 penetrating the substrate 610; four windings 631, 634, 635
  • the 638 is disposed on the front surface of the substrate 610.
  • the four windings 632, 633, 636, and 637 are disposed on the back surface of the substrate 610.
  • Each winding has two connection ends, and the connection between the windings is realized through the connection conductor and the via hole.
  • First and second phase current input terminal connection conductors 641 and 642 and current output terminal connection conductor 643 are formed in the substrate, and are connected to first and second phase current input terminal vias 661 of the current terminal connection conductor, The 662 and the current output terminal via 663 are used to connect the phase current.
  • the first phase current enters a connection end of the first winding 631 from the first phase current input terminal connection conductor 641 through the first phase current input terminal via 661, and passes through the other side of the first winding 631.
  • the connection end is connected to the first connection conductor 621 through the first via hole 6501.
  • the first connection conductor 621 is further connected to one end of the second winding 633 disposed on the back surface of the substrate 610 through the second via hole 6502, and the other via the second winding 633.
  • One end is connected to the second connecting conductor 622 through the third via 6503, and the second connecting conductor 622 is connected to one end of the third winding 635 on the front surface of the substrate 610 through the fourth via 6504, and passes through the other end of the third winding 635.
  • the fifth via 6505 is connected to the third connecting conductor 623, and the third connecting conductor 623 is further connected to one end of the fourth winding 637 disposed on the back surface of the substrate 610 through the sixth via 6506, and the other end of the fourth winding 637 passes through the current output terminal.
  • the vias 663 are connected to the current output terminal 643 so that they are sequentially connected to form a loop.
  • the second phase current flows from the second phase current input terminal connection conductor 642 through the second phase current input terminal via 662 to a connection end of the fifth winding 632 located on the back surface of the substrate 610, and passes through the other connection end of the fifth winding 632.
  • the seventh via 6507 is connected to the fourth connecting conductor 624, and the fourth connecting conductor 624 is further connected to one end of the sixth winding 634 provided on the front surface of the substrate 610 through the eighth via 6508, and via the other end of the sixth winding 634 via the sixth via 6508.
  • the ninth via 6509 is connected to the fifth connecting conductor 625, and the fifth connecting conductor 625 is connected to one end of the seventh winding 636 through the tenth via 6510, and the eleventh via 6511 and the other end via the seventh winding 636.
  • Six connecting conductors 626 are connected, and the sixth connecting conductor 626 is
  • the eighth winding 638 is connected to one end of the eighth winding 638 disposed on the other surface of the substrate 610 through the twelfth via 6512, and the eighth winding 638 is connected to the current output terminal connecting conductor 643 through the current output terminal via 663, thus sequentially connecting to form a current loop.
  • the eight windings can also be disposed on one side of the substrate at the same time, as shown in FIG. 6C, and details are not described herein again.
  • Embodiment 3 is a diagrammatic representation of Embodiment 3
  • FIG. 7A and FIG. 7B a schematic diagram of the installation of a three-phase current winding on a circuit board according to an embodiment of the present invention is shown.
  • the stator disk suitable for two-phase current comprises: a substrate 710.
  • the substrate 710 has a double-sided structure, and 12 windings can be respectively disposed on the front and back sides thereof, and have shaft holes for inserting the rotating shaft,
  • the connecting conductors 721-729 are formed in the substrate 710; the nine connecting conductors are respectively connected with 18 through holes 7501 to 7518 penetrating the substrate 710; the six windings 7301-7306 are disposed on the front surface of the substrate 710, and six windings 7307 to 7312 are disposed on the back surface of the substrate 710, and each of the windings has two connection ends, and the connection between the windings is realized by the connection conductors and the via holes.
  • First, second, and third phase current input terminal connection conductors 741, 742, and 743 and current output terminal connection conductor 744 are formed in the substrate, and first and second phase current inputs connected to the current terminal connection conductor Terminal vias 761, 762, 763 and current output terminal vias 764 are used to connect the phase currents.
  • the first phase current enters a connection end of the first winding 7301 from the first phase current input terminal connection conductor 741 through the first phase current input terminal via 761, and passes through the other of the first winding 7301.
  • the connection end is connected to the first connection conductor 721 through the first via hole 7501.
  • the first connection conductor 721 is further connected to one end of the second winding 7308 disposed on the back surface of the substrate 610 through the second via hole 7502, and the other via the second winding 7308.
  • One end is connected to the second connecting conductor 724 through the third via 7507, and the second connecting conductor 724 is connected to one end of the third winding 7304 located on the front surface of the substrate 710 through the fourth via 7508, and passes through the other end of the third winding 7304.
  • the fifth via 7513 is connected to the third connecting conductor 727, and the third connecting conductor 727 is further connected to one end of the fourth winding 7311 provided on the back surface of the substrate 710 through the sixth via 7514, and the other end of the fourth winding 7311 passes through the current output terminal.
  • Via 764 and electricity The stream output terminals 744 are connected such that they are sequentially connected to form a loop.
  • the second and third phase current connections are similar to those described above and will not be described again herein.
  • Each phase current in the three-phase power passes through four single coil windings, wherein two single coil windings are arranged opposite to one side of the substrate, and the other two single coil windings are arranged opposite to each other on the other side of the substrate, and the two sides are arranged in a crisscross type.
  • the four single coil windings of each phase current are ultimately connected to current output terminal 744 through output terminal via 764, which forms the closed end of the circuit.
  • a three-phase alternating current is supplied to the stator disk of the motor, and a magnetic field is generated around the current conductor according to the principle of electromagnetic induction, and a three-phase current winding of the three-phase alternating current flowing through the stator disk generates a rotating magnetic field in the motor (rotating magnetomotive force)
  • the permanent magnet of the rotor generated by the permanent magnet drives the rotor to rotate in the direction of rotation of the rotating magnetic field.
  • 12 windings can also be disposed on one side of the substrate at the same time, as shown in FIG. 7C, and details are not described herein again.
  • stator disk and the axial flux permanent magnet kinetic energy device provided by the embodiments of the present invention have the following obvious advantages:
  • the winding of the stator disc is a single independent winding coil, which does not require multiple coils to be continuously wound, has simple processing and high production efficiency.
  • the substrate for fixing the connected windings has a simple low-cost single-sided or double-sided design in which a connecting conductor is formed. A plurality of single coils, components, sockets connected to the controller, and the like are soldered to the substrate, and the mounting process is simple.
  • connection and mounting of the winding coils and the mounting and connection of other electronic components and connectors are realized by the substrate, thereby avoiding the overlap between the connecting wires and the coils in the conventional coil winding method, thereby effectively reducing the thickness of the stator disk.
  • the substrate thereby avoiding the overlap between the connecting wires and the coils in the conventional coil winding method, thereby effectively reducing the thickness of the stator disk.
  • the power and power density of the motor can be greatly improved, and the efficiency of the motor can be improved.

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Abstract

一种定子盘及轴向磁通永磁动能装置，其中定子盘包括：基板(110)，多个绕组(120)，至少一个连接导体(130)，和电流终端连接导体(140)；基板具有轴孔(111)；连接导体形成于基板中；多个绕组全部或部分独立，位于基板上，相互间独立的绕组通过连接导体全部或部分连接；电流终端连接导体形成于基板中，将绕组与相电流连接。

Description

定子盘及轴向磁通永磁动能装置 技术领域
本发明涉及电器设备技术领域，且特别涉及一种定子盘及轴向磁通永磁动能装置。
背景技术
定子无铁芯的轴向磁通盘式永磁(AFPM)电机，根据电磁感应原理，通电导体周围产生磁场，相电流流过定子的绕组会在电机里产生旋转磁场(旋转磁动势)，而永磁体的转子产生的转子主磁极如同一个磁铁，定子旋转磁场吸着永磁转子，按旋转磁场的旋转方向旋转，从而实现电机运转的目的。由于轴向磁通盘式永磁电机无铁芯，避免了因此造成的铁芯损耗，在此，铁芯损耗简称“铁耗”，又称“磁芯损耗”、“激励损耗”，是指磁性材料中由于存在交变或脉动磁场而引起的功率损耗，以热的形式表现，分为磁滞损耗和涡流损耗两部分，因而比常规的电机运转效率更高，而且其还具有体积小，重量轻，功率密度高，控制性能优良，加工制造简单等优点，此外，轴向磁通盘式永磁电机还可以通过不同数量的定子盘和永磁转子的配置，实现不同的功率要求，因此，轴向磁通盘式永磁电机具有广阔的应用前景。
然而，轴向磁通盘式永磁电机的气隙很小，为了改善轴向磁通盘式电机的电气特性，要求轴向磁通盘式永磁电机的定子盘厚度很薄且平坦。
现有的制造定子盘的方法主要包括线圈绕制定子盘和印刷电路板定子盘两种。
采用线圈绕制定子盘时，由于线圈之间的连接需要通过线圈连续绕制或者导线之间焊接连接来实现，批量生产的效率低，而且，在制作成定子盘时，内外边缘部分线圈之间的连接导线会与线圈重叠，使得边缘重叠部分厚度明显增加，定子盘不平坦，此外只能采用小线径线圈，电机功率较小。
而采用印刷电路板定子盘时，如美国专利US7109625，该专利涉及一种可 用作将电能转化为机械能的电动机或者将机械能转化为电能的发电机的优化轴向场转动能装置，其定子盘通过堆叠多个其中布置有多个电子部件的电路层，来达到设定功率和效率。由于其采用的定子盘完全由印刷电路板制造工艺制作，起作用的切割磁力线的导体线印刷在电路板上，线径受到较大限制，为了达到设定功率，需要多层电路板，且只能在小功率电机中应用，加工制作成本也较高。
发明内容
有鉴于此，本发明解决现有技术中，在轴向磁通盘式永磁电动机或发电机中，定子盘不平坦，导线线径小，功率较小，加工复杂，制作成本较高等技术问题。
本发明提供一种定子盘，其包括：基板，多个绕组，至少一个连接导体，和电流终端导体；所述基板具有轴孔；所述连接导体形成于所述基板中，所述多个绕组全部或部分独立，位于所述基板上，相互间独立的绕组通过所述连接导体全部或部分连接；所述电流终端连接导体形成于所述基板中，将所述绕组与相电流连接。
进一步的，所述绕组包括：第一绕边及第二绕边，其中所述第一绕边及第二绕边沿所述轴孔径向排布。
进一步的，所述绕组围绕所述轴孔呈辐射状排列。
进一步的，所述多个绕组为多个独立线圈。
进一步的，所述线圈线径为0.25至1.5毫米，每相绕组总匝数具有16至70匝。
进一步的，所述基板为单面，所述多个绕组分别位于所述基板的一面。
进一步的，所述基板为双面，所述多个绕组分别位于所述基板的两面。
进一步的，所述基板包括：连接于所述连接导体的贯穿所述基板的第一过孔及连接于所述电流终端连接导体的贯穿所述基板的第二过孔，用以连接位于所述基板上全部或部分绕组。
进一步的，所述基板为两个或两个以上，所述多个基板为叠加排列。
本发明还提供一种轴向磁通永磁动能装置，包括：多个具有多永久磁极的 转子以及如上所述的任一定子盘。
进一步的，所述多个转子分别设置于所述定子盘的两面，使得所述转子的永磁极磁场方向垂直于所述定子盘面。
进一步的，所述轴向磁通永磁动能装置的功率在50瓦至5000瓦。
综上所述，本发明提供的定子盘及轴向磁通永磁动能装置，所述定子盘采用的绕组为单一独立线圈，不需要多个线圈连续绕制，加工简单，生产效率高。用于固定连接绕组的基板采用简单的低成本的单面或双面设计，在该基板上焊接安装多个单一线圈、元器件、与控制器连接的插座，安装工艺简单。
其次，利用基板实现绕组线圈之间的连接和安装固定，以及其它电子元件和连接器的安装和连接，避免了绕组线圈之间的连接导线带来的重叠，有效降低了定子盘的厚度，保证了定子盘的平坦；同时，增加绕组线圈的线径，或增加安装有多个绕组的基板数，能提高电机的功率和功率密度，提高电机的效率。
附图说明
图1所示为本发明一实施例提供的定子盘的结构示意图；
图2所示为本发明一实施例提供的绕组的结构示意图；
图3所示为本发明一实施例提供的定子盘的结构示意图；
图4所示为本发明一实施例提供的轴向磁通永磁动能装置；
图5A所示为本发明一实施例提供的适用于单相电流定子盘的正面结构示意图；
图5B所示为本发明一实施例提供的适用于单相电流定子盘的背面结构示意图；
图5C所示为本发明一实施例提供的适用于单相电流单面定子盘的结构示意图；
图5D所示为本发明另一实施例提供的适用于单相电流单面定子盘的结构示意图；
图6A所示为本发明另一实施例提供的适用于两相电流定子盘的正面结构示意图；
图6B所示为本发明另一实施例提供的适用于两相电流定子盘的背面结构示 意图；
图6C所示为本发明一实施例提供的适用于两相电流单面定子盘的结构示意图；
图7A所示为本发明另一实施例提供的适用于三相电流定子盘的正面结构示意图；
图7B所示为本发明另一实施例提供的适用于三相电流定子盘的背面结构示意图；
图7C所示为本发明一实施例提供的适用于三相电流单面定子盘的结构示意图。
具体实施方式
为使本发明的目的、特征更明显易懂，下面结合附图对本发明的具体实施方式作进一步的说明。
鉴于现有技术中，在轴向磁通盘式永磁电动机或发电机中，存在定子盘不平坦，导线线径小，功率较小，加工复杂，制作成本较高等技术问题，本发明设计一种定子盘，其根据功率和电流相数的需求，利用一基板来连接和固定设置于基板上的绕组，从而实现了绕组线圈之间的连接，不仅工艺简单，降低了制造成本低，而且避免了传统线圈绕制法中连接导线和线圈间的重叠，有效降低了定子盘的厚度，保证了定子盘的平坦；同时，在有限的面积上，可以增加绕组线圈的线径，增加绕组线圈的匝数，或者增加安装有多个绕组的基板数，提高电动机和发电机的功率和功率密度，避免了印刷电路板定子盘线径小，功率小的缺点。
参见图1，其所示为本发明一实施例的定子盘的结构示意图。
在本实施例中，该定子盘，包括：基板110，多个绕组120，至少一个连接导体130，和电流终端连接导体140；所述基板110具有轴孔111；所述连接导体130形成于所述基板110中；所述多个绕组120全部或部分独立，位于所述基板110上，相互间独立的绕组120通过所述连接导体130全部或部分连接；所述电流终端连接导体140形成于所述基板110中，将所述绕组120与相电流连接。
该定子盘采用基板用于固定绕组，并通过设置于基板中的导体实现全部或部分绕组的连接，不仅工艺简单，成本低廉，而且避免了绕组的重叠，有效降低了定子盘的厚度，保证了定子盘的平坦。
在本发明实施例中，连接导体形成于基板中的方式可以但不限于下述方式：
(1)将连接导体按设计要求加工好之后嵌合或排布在基板中；
(2)在采用印刷电路板做为基板的情况下，使设计好的连接导体图案形成于印刷电路板中。
在采用上述(2)中所述的基板的情况下，由于印刷电路板加工简便，可以进一步提高生产效率和工艺稳定性。
参见图2，其所示为本发明一实施例提供的绕组的结构示意图。
在本发明实施例中，在定子盘中的所述绕组包括：第一绕边210及第二绕边220，其中所述第一绕边210及第二绕边220沿所述轴孔111径向排布，本发明实施例所述的沿轴孔径向的第一绕边及第二绕边是指在定子盘中起到作用的有效绕边，例如：绕组线圈可以是扇形、也可绕制成接近于椭圆形或方形，但其均有等效的沿所述轴孔的径向分布的垂直于磁场方向的起到作用的有效绕边，例如在电动装置应用领域中，当绕组通电时，在磁场中产生以轴孔为中心的磁场扭力，从而带动电机的转子发生转动，使电动装置工作。而在发电装置应用领域中，当永磁体转子转动时，会产生与绕组线圈交链的旋转磁转，从而在绕组线圈中感应出电动势。
参见图3，其所示为本发明一实施例的定子盘的结构示意图。
在本发明实施例中，所述绕组围绕310所述轴孔111呈辐射状排列，在提升绕组有效工作区域的同时避免了绕组的重叠，使各相电流互不干扰，避免交叉，且进一步降低了定子盘的厚度，保证了定子盘的平坦。
在本发明实施例中，所述多个绕组为多个独立线圈，在生产加工过程中，可以分别单独加工，使加工更加容易，避免了在现有技术中连续线圈绕制的难度，提高了生产效率，保证了加工质量，并且在保证电气特性的前提下，减小了多相电流之间的相互干扰，并且避免了绕组的重叠，有效降低了定子盘的厚度，保证了定子盘的平坦。
在本实施例中，绕组线圈可以根据功率的要求进行调整，在大功率电机的 配备上可以增加绕组线圈的线径，增加绕组线圈的匝数，进而提高电机的功率和功率密度，提高电机的效率，扩大了其适用范围。优选地，在本发明实施例中，所述线圈线径为0.25至1.5毫米，每相绕组的总匝数为16至70匝数。
在本发明实施例中，所述基板为单面，所述多个绕组分别位于所述基板的一面。
在本发明实施例中，所述基板为双面，所述多个绕组分别位于所述基板的两面。
在本发明实施例中，当所述基板为双面时，所述基板包括：连接于所述连接导体的第一过孔及连接于所述电流终端连接导体的第二过孔，以连接位于所述基板上全部或部分绕组。通过第一及第二过孔，使基板两面的全部或部分绕组线圈连接在一起，充分利用基板的容纳空间，提高功率密度。
在本发明实施例中，为了达到更大功率的使用要求，定子盘的所述基板为两个或两个以上，并且所述多个基板为叠加排列。由此可在多个基板上安装固定更多绕组，在工作时，输出更大的功率，以满足更大功率电机配置的需求。
参见图4，所示为本发明一实施例提供的轴向磁通永磁动能装置
在本发明实施例中，该轴向磁通永磁动能装置，包括：多个具有多永久磁极的转子410以及如上实施例所述的任一定子盘420。所述定子盘的结构如上述实施例所述，在此不再赘述。
在本发明实施例中，所述多个转子分别设置于所述定子盘的两面，使得所述转子的永磁极磁场方向垂直于所述定子盘面，当该轴向磁通永磁动能装置应用于电动装置领域时，定子盘通电时产生洛伦兹力驱动转子转动，使电动装置工作；当该轴向磁通永磁动能装置应用于发电装置领域时，当永磁极转子转动时，会产生与绕组线圈交链的旋转磁转，从而在绕组线圈中感应出电动势。
在本发明实施例中，所述轴向磁通永磁动能装置的功率在50瓦至5000瓦。
以盘式永磁无刷直流电动机为例，根据给定条件，确定样机的结构尺寸；结合工程设计需要及电磁分析结果选定气隙、磁轭厚度、极弧系数等相关参数；基于静磁场电磁分析获取相关磁密及磁通数值；空载反电势是基于降低定子电流，提高电机效率，降低电动机的温升并兼顾与额定电压的比值在一定的合理范围内选择的；由反电势公式算出每相绕组匝数，并考虑到绕组线圈个数的选 择，最终确定匝数，并确定出反电势；线径及绕组匝数综合考虑电密、电负荷、热负荷及槽满率等情况确定；依据电势常数和转矩常数，确定输出功率；轴承摩擦损耗和电枢对空气摩擦的损耗基于经验系数，铜耗基于电流、电阻计算；最后求出效率。根据确定的一系列参数，制作定子盘及样机并校验效率。
以下是根据上述设计方法设计的50瓦、1200瓦的具有上述实施例提供的定子盘的盘式永磁无刷直流电动机的具体参数：
Figure PCTCN2014094195-appb-000001
以下以盘式发电机为例，该具有上述实施例中的定子盘的盘式无铁心永磁同步发电机采用中间定子结构，即电机由双转子和单定子组成双气隙，电枢绕组是径向分布的，有效导体位于永磁体前方的面上，当永磁体由原动机拖动至同步转速时，将会在气隙中产生与电枢绕组交链的旋转磁转，从而在电枢绕组中感应出三相交流电动势。
根据确定的电机主要尺寸和绕组数据的时候，空载有效磁通、磁铁内部磁感应强度等数据后，在考虑流密度、电负荷、电枢绕组在定子盘空间内是否放得下等因素，该发电机的电枢绕组采用漆包铜圆线，裸线径为0.9mm，每相6个绕组，每相绕组总匝数为66匝；一共18个线圈，2面分布，每面9个线圈，最终使该采用上述实施例的定子盘的发电机的功率达到了5000瓦，转速达到3600rpm/min。
为了更加清楚地阐述本发明，以下结合具体实施例加以说明，以下实施例是以电动装置为例，然其并非用以限定本发明，任何所属技术领域中具有通常知识者在理解本发明实施例后，可以将该实施例稍做变形应用到发电装置中，同样适用于本发明实施例，在此不再赘述。
实施例一：
请结合参见图5A及图5B，其所示为本发明一实施例提供的单相电流绕组在电路板上的安装示意图。
该适用于单相电流的定子盘，包括：基板510，在该实施例中，基板510为双面结构，绕组分别设置于其正反两面，其具有轴孔用以穿插转轴，第一连接导体521、第二连接导体522及第三连接导体523形成于所述基板510中；电流输入终端连接导体541与电流输出终端连接导体542形成于所述基板510中，用以连接单相电流。
第一连接导体521、第二连接导体522及第三连接导体523上分别连接有贯穿基板的6个过孔551、552、553、554、555、556，所述电流终端连接导体541和542上分别连接有电路输入终端过孔561及电流输出终端过孔562。
在本实施例中，四个绕组531、532、533、534分别设置于基板510正反两面上，如图5A所示，第一绕组531及第三绕组533设置于基板510的正面；如图5B所示，第二绕组532及第四绕组534设置于基板510的反面。每个绕组具有两个连接端，并通过连接导体及过孔实现绕组之间的连接。当电流接通时，电流从电流输入终端连接导体541通过电路输入终端过孔561与第一绕组531的一连接端，经过第一绕组531的另一连接端通过第一过孔551与第一连接导体521连接，第一连接导体521再经由第二过孔552与位于基板510背面的第二绕组532的一端连接，经由第二绕组532的另一端通过第三过孔553与第二连接导体522连接，第二连接导体522通过第四过孔554与位于基板510正面的第三绕组533的一端连接，经由第三绕组533的另一端通过第五过孔555与第三连接导体523连接，第三连接导体523再经由第六过孔556与位于基板510背面的第四绕组534的一端连接，第四绕组534的另一端通过电流输出终端过孔562与电流输出终端连接导体542连接，这样依次连接形成电流回路。
当电流接通时，四个绕组中便会有持续电流流动，在垂直磁场的作用下产生围绕轴孔的旋转磁动势，带动转子转动。
在本发明另一实施例中，四个绕组也可以同时设置于基板的一面，由三个连接导体如图5C所示进行连接，在此不再赘述。
在本发明的另一实施例中，四个绕组也可以同时设置于基板的一面，由一个连接导体如图5D所示进行连接，在此不再赘述。图中虚线不代表任何意义。
实施例二：
请结合参见图6A及图6B，其所示为本发明一实施例提供的两相电流绕组在电路板上的安装示意图。
该适用于两相电流的定子盘，包括：基板610，在该实施例中，基板510为双面结构，8个绕组分别设置于其正反两面，其具有轴孔611用以穿插转轴，六个连接导体621、622、623、624、625、626形成于所述基板610中；六个连接导体上分别连接有贯穿基板610的12个过孔6501～6512；四个绕组631、634、635、638设置于基板610的正面，四个绕组632、633、636、637设置于基板610的背面，每个绕组具有两个连接端，并通过连接导体及过孔实现绕组之间的连接。第一及第二相电流输入终端连接导体641、642与电流输出终端连接导体643形成于所述基板中，连接于所述电流终端连接导体的第一及第二相电流输入终端过孔661、662及电流输出终端过孔663，用以连接相电流。
当两相电流接通时，第一相电流从第一相电流输入终端连接导体641通过第一相电流输入终端过孔661进入第一绕组631的一连接端，经过第一绕组631的另一连接端通过第一过孔6501与第一连接导体621连接，第一连接导体621通过第二过孔6502再与设置于基板610背面的第二绕组633的一端连接，经由第二绕组633的另一端通过第三过孔6503与第二连接导体622连接，第二连接导体622通过第四过孔6504与位于基板610正面的第三绕组635的一端连接，经由第三绕组635的另一端通过第五过孔6505与第三连接导体623连接，第三连接导体623再通过第六过孔6506与设置于基板610背面的第四绕组637的一端连接，第四绕组637的另一端通过电流输出终端过孔663与电流输出终端643连接，这样依次连接形成回路。
第二相电流从第二相电流输入终端连接导体642通过第二相电流输入终端过孔662进入位于基板610背面的第五绕组632的一连接端，经过第五绕组632的另一连接端通过第七过孔6507与第四连接导体624连接，第四连接导体624通过第八过孔6508再与设置于基板610正面的的第六绕组634的一端连接，经由第六绕组634的另一端经由第九过孔6509与第五连接导体625连接，第五连接导体625通过第十过孔6510与第七绕组636的一端连接，经由第七绕组636的另一端经由第十一过孔6511与第六连接导体626连接，第六连接导体626再 通过第十二过孔6512与设置于基板610另一面上第八绕组638的一端连接，第八绕组638通过电流输出终端过孔663与电流输出终端连接导体643连接，这样依次连接形成电流回路。
当两相电流接通时，八个绕组中便会有持续电流流动，根据电磁感应原理，通电导体周围产生磁场，在垂直磁场的作用下产生围绕轴孔的旋转磁动势，从而带动转子转动。
在本发明另一实施例中，8个绕组也可以同时设置于基板的一面，如图6C所示，在此不再赘述。
实施例三：
请结合参见图7A及图7B，其所示为本发明一实施例提供的三相电流绕组在电路板上的安装示意图。
该适用于两相电流的定子盘，包括：基板710，在该实施例中，基板710为双面结构，12个绕组可分别设置于其正反两面，其具有轴孔用以穿插转轴，九个连接导体721～729形成于所述基板710中；九个连接导体上分别连接有贯穿基板710的18个过孔7501～7518；六个绕组7301～7306设置于基板710的正面，六个绕组7307～7312设置于基板710的背面，每个绕组具有两个连接端，并通过连接导体及过孔实现绕组之间的连接。第一、第二及第三相电流输入终端连接导体741、742、743与电流输出终端连接导体744形成于所述基板中，连接于所述电流终端连接导体的第一及第二相电流输入终端过孔761、762、763及电流输出终端过孔764，用以连接相电流。
当三相电流接通时，第一相电流从第一相电流输入终端连接导体741通过第一相电流输入终端过孔761进入第一绕组7301的一连接端，经过第一绕组7301的另一连接端通过第一过孔7501与第一连接导体721连接，第一连接导体721通过第二过孔7502再与设置于基板610背面的第二绕组7308的一端连接，经由第二绕组7308的另一端通过第三过孔7507与第二连接导体724连接，第二连接导体724通过第四过孔7508与位于基板710正面的第三绕组7304的一端连接，经由第三绕组7304的另一端通过第五过孔7513与第三连接导体727连接，第三连接导体727再通过第六过孔7514与设置于基板710背面的第四绕组7311的一端连接，第四绕组7311的另一端通过电流输出终端过孔764与电 流输出终端744连接，这样依次连接形成回路。
第二及第三相电流连通与如上所述类似，在此不再赘述。
三相电中每相电流均经过四个单一线圈绕组，其中两个单一线圈绕组相对布置在基板的一面，另外两个单一线圈绕组相对布置在基板的另一面，两面的排布为十字交叉型；每相电流的四个单一线圈绕组最终通过输出终端过孔764与电流输出终端744连接，该输出终端形成电路的封闭端。
由此，在电机的定子盘通入三相交流电，根据电磁感应原理，通电导体周围产生磁场，三相交流电流流过定子盘的三相电流绕组会在电机里产生旋转磁场(旋转磁动势)，而永磁体产生的转子主磁极按旋转磁场的旋转方向带动转子旋转。
在本发明另一实施例中，12个绕组也可以同时设置于基板的一面，如图7C所示，在此不再赘述。
综上所述，本发明实施例提供的定子盘及轴向磁通永磁动能装置，具有以下的明显优点：
首先，所述定子盘采用的绕组为单一独立绕组线圈，不需要多个线圈连续绕制，加工简单，生产效率高。用于固定连接绕组的基板采用简单的低成本的单面或双面设计，连接导体形成于所述基板中。在该基板上焊接安装多个单一线圈、元器件、与控制器连接的插座等，安装工艺简单。
其次，利用基板实现绕组线圈之间的连接和安装固定，以及其它电子元件和连接器的安装和连接，避免了传统线圈绕制法中连接导线和线圈间的重叠，有效降低了定子盘的厚度，保证了定子盘的平坦。在采用基板双面布置线圈的方式下，还能够避免绕组线圈之间重叠所造成的电流之间的干扰，大幅提升电气特性；
第三，通过增加绕组线圈的线径，或增加安装有多个绕组的基板数，能大幅度提高电机的功率和功率密度，提高电机的效率。
虽然本发明已以较佳实施例揭露如上，然其并非用以限定本发明，任何所属技术领域中具有通常知识者，在不脱离本发明的精神和范围内，当可作各种的变动与润饰，因此本发明的保护范围当视权利要求书所界定者为准。

Claims (12)

  1. 一种定子盘，其特征在于，包括：
    基板，多个绕组，至少一个连接导体，和电流终端连接导体；
    所述基板具有轴孔；
    所述连接导体形成于所述基板中；
    所述多个绕组全部或部分独立，位于所述基板上，相互间独立的绕组通过所述连接导体全部或部分连接；
    所述电流终端连接导体形成于所述基板中，将所述绕组与相电流连接。
  2. 根据权利要求1所述的定子盘，其特征在于，所述绕组包括：第一绕边及第二绕边，其中所述第一绕边及第二绕边沿所述轴孔径向排布。
  3. 根据权利要求1所述的定子盘，其特征在于，所述绕组围绕所述轴孔呈辐射状排列。
  4. 根据权利要求1所述的定子盘，其特征在于，所述多个绕组为多个独立线圈或部分独立线圈。
  5. 根据权利要求4所述的定子盘，其特征在于，所述线圈线径为0.25至1.5毫米，每相绕组的总匝数具有16至70匝。
  6. 根据权利要求1所述的定子盘，其特征在于，所述基板为单面，所述多个绕组分别位于所述基板的一面。
  7. 根据权利要求1所述的定子盘，其特征在于，所述基板为双面，所述多个绕组分别位于所述基板的两面。
  8. 根据权利要求1所述的定子盘，其特征在于，所述基板包括：连接于所述连接导体的贯穿所述基板的第一过孔及连接于所述电流终端连接导体的贯穿所述基板的第二过孔，用以连接位于所述基板上全部或部分绕组。
  9. 根据权利要求1所述的定子盘，其特征在于，所述基板为两个或两个以上，所述多个基板为叠加排列。
  10. 一种轴向磁通永磁动能装置，其特征在于，包括：多个具有多永久磁极的转子以及如权利要求1至9所述的任一定子盘。
  11. 根据权利要求10所述的轴向磁通永磁动能装置，其特征在于，所述多 个转子分别设置于所述定子盘的两面，使得所述转子的永磁极磁场方向垂直于所述定子盘面。
  12. 根据权利要求10所述的轴向磁通永磁动能装置，其特征在于，所述轴向磁通永磁动能装置的功率在50瓦至5000瓦。
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