U.S. patent number RE35,763 [Application Number 08/685,271] was granted by the patent office on 1998-04-07 for permanent magnet excited electric motor.
This patent grant is currently assigned to Papst-Motoren GmbH & Co. KG. Invention is credited to Martin Burgbacher.
United States Patent |
RE35,763 |
Burgbacher |
April 7, 1998 |
Permanent magnet excited electric motor
Abstract
A permanent magnet excited motor is provided with a plurality of
low circumferential hump-like protrusions on the face of each
stator pole to partially decrease the air gap between the stator
and rotor and act as so-called magnetic cams to exert a force on
the rotor to smooth an otherwise uneven parasitic slot torque that
occurs between the interaction of slot openings of the stator poles
and the gaps between the permanent magnet poles of the rotor.
Inventors: |
Burgbacher; Martin (St.
Georgen, DE) |
Assignee: |
Papst-Motoren GmbH & Co. KG
(DE)
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Family
ID: |
25840080 |
Appl.
No.: |
08/685,271 |
Filed: |
July 23, 1996 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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353648 |
Dec 8, 1994 |
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218397 |
Jul 13, 1988 |
4998032 |
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140976 |
Jan 6, 1988 |
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02957 |
Jan 13, 1987 |
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Reissue of: |
665525 |
Mar 5, 1991 |
05170083 |
Dec 8, 1992 |
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Foreign Application Priority Data
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Jan 13, 1986 [DE] |
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3600737 |
Jul 13, 1987 [DE] |
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3723099 |
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Current U.S.
Class: |
310/51;
310/156.01; 310/193; 310/254.1 |
Current CPC
Class: |
H02K
29/03 (20130101); H02K 21/14 (20130101); H02K
21/22 (20130101) |
Current International
Class: |
H02K
29/03 (20060101); H02K 21/14 (20060101); H02K
21/22 (20060101); H02K 005/24 () |
Field of
Search: |
;310/49R,51,67R,156,179,186-188,190,193,216,218,254,261,264,265,269 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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0182702 |
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May 1986 |
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EP |
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0169569 |
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Nov 1990 |
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EP |
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2031141 |
|
Dec 1971 |
|
DE |
|
3112360 |
|
Nov 1982 |
|
DE |
|
2823208 |
|
Aug 1984 |
|
DE |
|
58-42707 |
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Sep 1983 |
|
JP |
|
Primary Examiner: Budd; Mark O.
Attorney, Agent or Firm: Welsh & Katz. Ltd.
Parent Case Text
This application .Iadd.is a continuation of application Ser. No.
08/353,648, filed Dec. 8, 1994, now abandoned, which is a
continuation of application .Iaddend.is a continuation of Ser. No.
07/218,397, filed Jul. 13, 1988, now U.S. Pat. No. 4,998,032 which
is a continuation-in-part of U.S. Ser. No. 07/140,976, filed Jan.
6, 1988, now abandoned, which is a continuation of U.S. Ser. No.
07/002,957 filed Jan. 13, 1987, now abandoned.
Claims
I claim:
1. A brushless dc motor having a cylindrical type air gap, a
slotted stator core and permanent magnet excitation, the air gap
being defined between circumferentially facing faces of the slotted
stator core and an opposing ring of permanent magnets formed to
rotate with respect to the core, the core having a plurality of
radially extending winding slots, and the motor including at least
one winding forming electromagnetic poles defined in the sectors
between slots of the stator core with a plurality of raised
portions on each of the electromagnetic pole faces extending
radially into the air gap, the circumferential width of the raised
portions being small compared to the circumferential width of the
pole pitch, the raised portions on each of the pole faces being
located such that the distance measured in the direction of rotor
rotation from the center of a stator slot defined between any given
pair of stator poles to the center of one of said raised portions
on the stator face adjacent said given pair of stator poles is
equal to n times the rotor pole pitch, n being a whole number.
2. A motor according to claim 1, wherein the circumferential extent
of the raised portion corresponds to from 0.5 to 1 times the
circumferential width of the stator slot orifice.
3. A motor according to claim 1, wherein the air gap directly next
to the raised portion as seen in the circumferential direction has
the maximum dimension, which dimension decreases in the direction
of the stator pole ends, preferably to a value equal to that above
the cog.
4. A motor according to claim 3, wherein the height of the raised
portion is from 0.1 to 0.3 mm with an effective air gap of from 0.3
to 0.6 mm.
5. A motor according to claim 3, wherein the reduction in air gap
dimension is gradual and continuous.
6. A motor according to claim 5, wherein the air gap next to the
raised portion soon decreases drastically in dimension, then
increases again near the stator pole ends and finally decreases
directly at the stator pole ends.
7. A motor according to claim 1, wherein the rotor is an internal
rotor. .Iadd.8. A brushless dc motor having a cylindrical type air
gap, a slotted stator core and permanent magnet excitation, the air
gap being defined between circumferentially facing faces of the
slotted stator core and an opposing ring of permanent magnets
formed to rotate with respect to the core, a pole gap being defined
between each adjacent pair of said permanent magnets, the core
having a plurality of radially extending winding slots and a
corresponding plurality of stator slot orifices, and the motor
including at least one winding forming electromagnetic poles
defined in the sectors between slots of the stator core wherein a
parasitic torque is generated each time that a pole gap interacts
with one of said stator slot orifices, the motor further including
a plurality of raised portions on each of the electromagnetic pole
faces extending radially into and thereby reducing the air gap, the
circumferential width of the raised portions being small compared
to the circumferential width of the pole pitch, the raised portions
on each of the pole faces being (i) dimensioned and positioned
thereon to generate a compensating torque which corresponds to and
is generally opposite to one of said parasitic torques and (ii)
located such that the distance measured in the direction of rotor
rotation from the center of a stator slot defined between any given
pair of stator poles to the center of one of said raised portions
on the stator face adjacent said given pair of stator poles is
equal to n times the rotor pole pitch, n being a non-negative and
non-zero whole number. .Iaddend..Iadd.9. A motor according to claim
8, wherein the circumferential extent of the raised portion
corresponds to from 0.5 to 1 times the circumferential width of the
stator slot orifice. .Iaddend..Iadd.10. A motor according to claim
9, wherein the air gap directly next to the raised portion as seen
in the circumferential direction has the maximum dimension, which
dimension decreases in the direction of the stator pole ends,
preferably to a value equal to that above the cog.
.Iaddend..Iadd.11. A motor according to claim 10, wherein the
height of the raised portion is from 0.1 to 0.3 mm with an
effective air gap of from 0.3 to 0.6 mm. .Iaddend..Iadd.12. A motor
according to claim 10, wherein the reduction in air gap dimensions
is gradual and continuous. .Iaddend..Iadd.13. A motor according to
claim 12, wherein the air gap next to the raised portion soon
decreases drastically in dimension, then increases again near the
stator pole ends and finally decreases directly at the stator pole
ends. .Iaddend..Iadd.14. A motor according to claim 8, wherein the
rotor is an internal rotor. .Iaddend.
Description
This invention concerns a permanent magnet excited dynamo machine
with a slotted core, especially a small brushes dc motor with
permanent magnetic rotor poles of a relatively high induction.
In motors of this type, so-called permanent magnet excited machines
(PMEM), interfering or parasitic torques develop because of the
interaction between the slots and the edges of the magnetized poles
and prevent smooth running of the machine. If the gap between the
magnetized poles is smaller, the interfering or parasitic uneven
torque component (so-called slot torque unevenness) tends to be
greater.
If motors of this type are to be used in signal processing units
with specifications for an extremely compact design, one is forced
to use especially strong permanent magnets for the rotor, so-called
"rare earth magnets," e.g., those of a samarium cobalt alloy. When
such a motor is used for disk memory where the storage plate is
only 3.5 or 51/4 inches and must also be located inside the disk
hub (with an outside diameter of 40 mm or even as little as 25 mm),
i.e., when a relatively high power must be obtained from such a
small structural volume, a polyphase winding is used in addition to
a rare earth magnet for high air gap induction although this is not
easy to manufacture because of the extremely small size. The
essentially cylindrical air gap is then generally located radially
outside the cylindrical outer surface of the stator so it is around
the stator and the radial gap is relatively small even in the case
of an external rotor motor.
In this application, a primary purpose is to improve the practical
examples according to FIGS. 4 to 6. Among other things, a version
with a larger number of rotor poles is to be considered here.
Permanent magnetic rotors for such motors are often built from thin
half-shells or quarter-shells or radially thin axially stacked
rings. The radial thinness of these rotor magnetic comes from the
very limited diameter of the motor. For extremely small, high power
motors, the air gap must also be minimized (air gap: average
distance with an electromotor effect between the iron surface of
the stator and the iron surface of the rotor). Thus with the
combination of high induction, slotted stator and the smaller
possible air gap, this leads the problem of reducing or preventing
if possible the so-called slot torque unevenness which causes
problems in a motor with the most constant possible torque. At the
same time because of the danger of grazing or because of the
manufacturing expense, a "minimum mechanical size" is needed for
the air gap.
If the permanent magnetic rotor is also to be magnetized
trapezoidally, this offers power advantages but at the same time
the problem becomes even more severe in comparison with the
conditions with sinusoidal magnetization.
It is known from German document DE-OS No. 2,832,208 that a certain
periodicity can be provided in the stator surface at the air gap in
order to reduce the third harmonic in the torque so the air gap is
varied in a periodic manner over the periphery.
This invention is based on the problem of achieving even smoother
operation of motors of the type defined initially despite the high
field concentration in the air gap. In addition, especially the
average air gap (see above definition) should also be reduced.
Motors with a larger number of poles should also be optimized.
The short peripheral elevations (hump-like protrusions) according
to this invention narrow the air gap partially above the stator
pole and act like "magnetic cogs," exerting forces on the rotor
that are utilized to even out the torque. The cross section of
these cogs is approximately rectangular and is in (or at) the
middle of each stator pole in an important version of this
invention.
This invention will now be explained in a preferred version with
the motors mentioned initially having a cylindrical air gap and
slotted stator with a multiphase winding without any overlap.
The figures show the following:
FIG. 1a shows a developed longitudinal section of a motor according
to this invention in a first version whereby the ratio or the
number of stator poles to the number of rotor poles is 3 to 2.
FIG. 1b shows a diagram of problem causing slot torque unevenness 1
and the course of the useful torque component 2 according to this
invention.
FIG. 1c shows combined curves 1 and 2.
FIG. 1d is an enlargement of a portion of FIG. 1a.
FIGS. 2a, 2b show an alternative element or an element to be used
in addition with an effect similar to that of the first practical
example according to FIG. 1a.
FIGS. 3a and 3b show an easy to manufacture alternative solution to
FIGS. 2a and 2b, where FIGS. 2a and 3a each show the end view in
axial direction and FIGS. 2b and 3b each show a section through the
diagrams according to FIGS. 2a and 3a.
FIG. 4 essentially shows the first variation according to FIG. 1a
approximately four times natural size where the air gap is tapered
toward the stator pole end where it matches the cylindrical surface
which also surrounds the elevations according to this
invention.
FIG. 5 shows a second version, where ends tapering radially in a
point toward the pole end are provided.
FIGS. 6a and 6b show the stator contours of .[.FIG..]. .Iadd.FIGS.
.Iaddend.4 and 5 in an enlarged diagram.
FIGS. 7 and 8 illustrate how another version operates. FIGS. 9a,
9b, 9c, and 9d relate generally to an internal rotor motor of the
invention showing a plurality of raised portions on each of the
stator poles.
In detail, FIG. 1a shows the partial developed view of a 6-pole
stator with concentrated poles 11, 12, 13 and a 4-pole rotor with
the permanent magnet poles 21, 22, 23 between which the
peripherally narrow pole gaps 25 and 26 are arranged, while the
stator slot orifices 14, 15 with their width `s` indicate the
distance between two stator pole ends. Looking concentrically
toward the middle of each stator pole one can see the magnetic cogs
3 (numbers 113, 123, 133) with their peripheral dimension `a` and
height `h`. Between the stator 10 and the rotor 20, there is the
air gap 30 bordered by the stator pole heads and the permanent
magnets of the rotor 21, 22, 23. A soft magnetic short-circuit
layer 24 surrounds the four rotor poles 21ff. With rotation, i.e.,
movement of rotor 20 in the direction of arrow 27, the problem
causing .[.wherein.]. .Iadd.uneven .Iaddend.parasitic torque
effect, i.e., the unevenness torque component according to curve 1
in FIG. 1b, occurs due to the interaction of the stator slot
orifice 14 and the rotor pole gap 25. At the same time, an uneven
torque component in phase opposition according to curve 2 also
occurs at the distance of the rotor pole pitch .tau..sub.p rotor
due to the interaction of the magnetic cog 133 with the rotor pole
gap 26, and namely this occurs in the area of the rotor pole gap
26. FIG. 1c shows the superposition of curves 1 and 2. The
instantaneous curve of the damaging uneven parasitic slot torque
effect occurs when the permanent magnet of a high induction, e.g.,
21, travels with its end (in the area of pole gap 25) away from
stator pole 11 over the open slot 14 to the next stator pole
12.
This has been confirmed by measurements which have shown that when
the edge of slot 14, for example, is between the poles, e.g.,
between 21 and 22, the maximum unevenness occurs as shown by the
shape of curve 1 in FIG. 1b. Therefore, the distance between the
peaks in curve 1 corresponds to the width `s` of the slot orifices,
e.g., 14.
In order to adapt the distance `b` of the peaks of the compensation
.[.moment.]. .Iadd.component .Iaddend.(curve 2) of cogs 3 according
to this invention to this distance `s`, it is important to optimize
the cog width `a` in this sense, because the problem-causing torque
(curve 1) is fully compensated by curve 2 for b=s. This optimum cog
width is in the range of `a`=0.5 to 1.times.s but is influenced by
the inductance pattern of the permanent magnet.
It has thus been found that uneven torque components which have
almost the same diagram as those of the slot openings or orifices
(see curve 1) with appropriate dimensioning and positioning of the
"magnetic cogs" (3) can likewise be produced. If these "cogs" are
arranged in such a way that their average distance from the
respective slot opening is equal to one pole pitch of the rotor (p)
or an integral multiple thereof, then the uneven torque component
of the "cogs" is in inverse ratio to that of the slots, i.e., the
unevenness is compensated (see curve 2).
The peripheral width `a` of this cog, i.e., its dimension in
peripheral direction, may amount to only a small fraction of the
stator pole pitch. There is an optimum between this peripheral
width `a` of the cog and the slot width s between these stator
poles (or stator heads) so even a very small cog width `a` also
permits a simultaneous enlargement of the slot because the
conditions are otherwise the same (which facilitates manufacturing
of the windings).
Especially with a 6-slotted motor for a 3-phase winding with four
rotor poles as disclosed in German document DE-OS No. 3,122,049, it
is found that this invention yields an excellent reduction in this
unwanted slot torque unevenness.
Optimization experiments have shown that narrowing the air gap
toward the ends of the stator heads through locations that project
radially, e.g., points on the stator pole end as shown from German
document DE-OS 2,919,581 or 3,049,494 with so-called reluctance
motors yields another improvement for the present problem.
Providing the stator heads with pointed ends 6 according to FIG. 5
have an effect similar to that of cogs. But since their distance A
is always larger than the slot orifice width `s`.Iadd.,
.Iaddend.their curve 2.sup.x has a smaller amplitude and their
position is also shifted away from the middle of the slot. This
results in a relatively large harmonic which is why these points
are optionally combined with an even narrower cog (a.sup.x
=0.3.multidot.S to 0.8.multidot.S). It has surprisingly been found
that the same ratios are achieved with a reduced cog height h.sup.x
=0.05 to 0.2 mm at the same time and thus a further favorable
reduction in the average air gap width is possible.
In FIGS. 1a and 1b, this is illustrated by representing .[.t.].
.Iadd.this .Iaddend.second solution with a dash-dot/dotted line.
The compensation effect of the attached tips 111, 112 corresponds
to curve 2.sup.x, and the compensation effect of the cam 3.sup.x
which is shorter in the periphery corresponds to curve 2.sup.xx
(see FIG. 1b). Both effects take place simultaneously with the
overall effect as illustrated in curve 2 but this result occurs at
a smaller h.sup.x, so the average air gap is smaller and the motor
is stronger. This surprising refinement is all the more welcome
since a certain oversize must be added for manufacturing tolerances
in addition to the minimum theoretical air gap in designing motors
and with regard to the air gap in motors of this small size, each
1/10 mm is important.
The cog height `h` determines the height (amplitude) of the
maximum. This can be implemented as part of the usual air gap
widths (0.3 mm to 0.6 mm) as h=0.1 mm to 0.3 mm high accordingly
(case shown in FIG. 4). In order to minimize the average increase
in air gap caused by the presence of cogs, it is also proposed that
the diameter from the slot opening be increased continuously to
that of the cog diameter in accordance with FIG. 4.
As an alternative or in addition, a "cog-like" effect can already
be achieved in the slotted area by means of magnetic closing
thereof by means of ferromagnetic slot parts as known from German
document DE-AS No. 1,194,043.
Essentially it seems possible to apply this invention to slotted
rotor packages as well. When these rotate in the field of permanent
magnets (then on the stator side), smooth running can also be
improved there. However, this version means that a mechanical
collector is required. In special applications, motors used, may
also need an improvement in running properties by reducing the slot
torque unevenness.
FIG. 2a shows ferromagnetic angles 33 riveted onto the stator core
with their axial legs 34 projecting beyond the core 36 so the air
gap between them and the outer rotor magnet N is reduced.
Therefore, these axially directed legs 34 act like magnetic cogs
according to this invention in the middle of the pole. This
solution is definitely a compromise because on the whole this means
that the effective air gap between the rotor and sector (N, 36) is
relatively large. However, no special punching tool need be
provided to produce the core 36. The angles are attached axially on
both sides to the ends of the stator core as illustrated in FIG.
2b. However, the rotor magnet which projects axially together with
the angles 33 projecting axially beyond the stator core, especially
axial leg 34, yield an effective and inexpensive application of
this invention or may even effectively improve an arrangement
according to FIG. 1.
FIGS. 3a and 3b show how the angle 34 can be replaced by end plates
with angled axially projecting tabs 37.
FIGS. 5 and 6b show a reduction in air gap toward the stator pole
ends (as indicated with a dash-dot line in FIG. 1a), so the peaks
of the respective torque effects (curves 2.sup.x) are further apart
(corresponding to the distance A) than the slot orifice width `s`.
This effect was explained in connection with FIG. 1. A circular
cylindrical elevation 102, 105 toward the cylindrical sheathing
surface 103 starting from the recess next to cog 3.sup.x and
extending to the recess next to the tip 111 at the stator pole end
is provided in the area around the middle between the respective
stator pole middle and any stator pole end so the average air gap
diameter is effectively reduced (see FIG. 6b stator pole ST II).
The radius of curvature R of this elevation 102, 105 is much
smaller than that of the enveloping surface 103, 100, 104 (FIGS.
6a, 6b). The midpoint M of the curvature 102, 105 is located
between the rotor axis and the stator pole head.
FIG. 5 shows primarily cylindrical concentric stator pole faces
whose midpoint of curvature is in the rotor axis (as shown more
clearly by areas 100, 101 in stator version ST III in FIG. 6b).
The relationships illustrated in FIG. 6b will be further optimized
according to this invention.
In FIGS. 7 and 8, operation according to this invention is
illustrated further by comparing the conditions here on a 6-pole
external stator and a 4-pole internal rotor, namely the uneven slot
torque components and their reduction, their superposition as they
actually occur in the example shown here, e.g., at the 12:00
o'clock position or at the 3 o'clock position. At the 12:00 o'clock
position, one north pole reaches the area of the stator pole middle
and at the 3:00 o'clock position one north pole, for example,
leaves the slot middle area. These two pulsating components are
mutually superimposed in a decelerating and driving manner so they
cancel each other out. The conditions in the area of the stator
pole middle at the 12:00 o'clock position are illustrated in FIG. 7
and the conditions in the slot area at the 3:00 o'clock position
are shown in FIG. 8. Subfigures 7a, 8a show the stator contour with
the air gap enlargement areas T.sub.1, T.sub.2 and T.sub.3 as
defined in the description and in the claims. Curves 1a-1d show the
slot pressure moments which occur when only one cog is provided in
the stator pole middle and the stator pole head area is also
cylindrical. If indentation T.sub.1 is placed next to the cog and
indentation T.sub.2 is placed in front of the stator pole end as
described above.Iadd., .Iaddend.the pulsating component is reduced
so the height of the cog can be greatly reduced so its outer face
toward the air gap is at approximately the same level as the tip of
the stator pole at its end. In this way, a drastic air gap
reduction is already achieved as described above. These two
components are illustrated by curve 2. The curves 2 and 2' then do
not yield a zero line as the sum of 1 and 1' but instead this sum
curve for 2 and 2' has a certain waviness which is a relative
disadvantage, but this effect can be further reduced or eliminated
by providing a relative air gap enlargement T.sub.3 between the
stator pole middle and the stator pole end which is about 1/10 the
stator pole width in the circumferential direction and on the whole
is much smaller than the air gap enlargement next to the cog and at
the pole arc end. Because .Iadd.of .Iaddend.this enlargement
T.sub.3, the waviness in the sum group 2 and 2' can be further
reduced, and again we have a sum moment of zero. This means that
the average air gap reduction can be accomplished without the
disadvantages of such a pulsating extra component.
FIG. 9a shows a complete stator section with six outer stator poles
for an 8-pole inner rotor as shown in FIG. 9c. According to this
invention, three .[.cogs-303.]. .Iadd.cogs 303 .Iaddend.are
provided on each stator pole 311-316 in such a way that one sits
centrally in the middle of the stator pole and another cog sits
between the middle of the stator pole and the middle of one slot
317-322 so there is an equidistant distribution of three cogs 303
between two stator slots (adjacent). Between two adjacent cogs 303
or between one cog 303 and the adjacent stator pole end, the finer
refinements as described above in combination with FIGS. 4 to 7 can
also be used in addition.
FIG. 9b shows the dimensional relationships of a single stator pole
in an enlarged detail. The cog height `h` here may be 0.2 mm. The
cog width `a` in the peripheral direction may be 1.8 mm. The
mechanical distance between two cogs and between one cog and the
adjacent slot is 15 mechanical degrees. The air gap diameter may be
about 50 mm.
FIGS. 7a and 8a also show the additional recess in the middle
between the cog in the center of the stator pole and the adjacent
slot as about 1.1 mm with an air gap diameter of about 50 mm.
FIG. 9, i.e., FIGS. 9a to 9d, show a practical example with an
8-pole rotor of the motor with 6 slots in the stator.
With a larger number of poles, each slot can be compensated by
several cogs, e.g., three shown in FIG. 9. In this way the cog
height can be reduced to 1/3 the height that would otherwise be
required in the embodiments of FIGS. 1 to 8.
This invention can fundamentally also be used with other air gap
forms, e.g., with a planar air gap, but this form of implementation
requires additional measures because the stator pole width must be
varied in the longitudinal direction of the slot, for example.
FIG. 9c shows an enlarged and more complete computer printout of
the parts of the magnetic circuit for the practical example
according to FIG. 9a where the laminated stator 300, the internal
rotor 200 with its 8 permanent magnet poles 201 can be seen mounted
on the magnetic flux return path 202 which is preferably designed
as a soft iron hollow cylinder.
FIG. 9d shows a detail of an enlarged cutaway sector indicated as
IXd in FIG. 9c. The field line pattern was also printed out by
computer. Cutouts 304, 305 and 306 distributed uniformly on the
outer perimeter of the stator yoke can be used for mounting in a
motor casing, e.g., by having the parts of the motor casing fit in
a form locking manner into these cutouts.
The six stator poles are each provided with a concentrated winding
(not shown) where two diametrically opposed windings are excited
simultaneously, e.g., by having the two windings connected in
series.
* * * * *