• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    It is a pancake motor (1, 26) having at least one stator (3, 4, 28, 31) of the at least one electric stator winding (14) and stator teeth (11) forming a tooth neck (12) of a soft magnetic powder composite material, and shown with at least one disc-shaped rotor (2, 27), the permanent magnetic poles (9) formed exclusively by ferrite magnets (7, 8) at least for torque generation, said rotor (2, 27) and stator (3, 4, 28, 31) oriented parallel to each other and spaced by an axial gap (5). In order to find an optimum between costs, weight or size and power and torque density, the invention proposes that the stator teeth (11) in each of a tooth neck (12) adjoining tooth end (15) of a soft magnetic powder composite material end, which tooth end (15) widens in relation to the tooth neck (12) in its cross-sectional area (AE).
    公开号:AT514709A1
    申请号:T50510/2013
    申请日:2013-08-16
    公开日:2015-03-15
    发明作者:Ralf Dipl Ing Kobler；Dietmar Dipl Ing Andessner；Christian Dipl Ing Sandner
    申请人:Johannes Kepler Universität Linz；
    IPC主号:
    专利说明:

    The invention relates to a pancake motor having at least one stator, which has at least one electric stator winding and stator teeth forming a tooth neck made of a soft magnetic powder composite material, and having at least one disc-shaped rotor having exclusively formed by ferrite permanent magnetic poles for torque generation, said rotor and Stator oriented parallel to each other and spaced from each other by an axial gap.
    In order to provide a reduced material cost pancake motor, it is known in the art (Author: Sone, Kodai et al., Title: "A Ferrite PM In-Wheel Motor Without Rare Earth Materials", IEEE Transactions on Magnetics, 48 (11): 2961-2964), to equip a rotor designed as a rotor disk exclusively with ferrite magnets, so as to form the permanent magnetic poles for torque generation. The need for rare earth existing permanent magnets can be avoided, which leads not only to reduced costs but also to pancake motors with comparatively low eddy current losses. The rotor is, as usual in pancake motors, oriented parallel to the stator and spaced by an axial gap from the stator. The stator yoke of the stator is made of a soft magnetic powder composite material and forms stator teeth with wound and blunted tooth necks. A disadvantage must be expected when using inexpensive ferrite magnet on the one hand with reduced power densities, on the other hand with lower torque densities. Increased diameter on the rotor disc can compensate for this - but increase the anyway by this engine concept comparatively large space with respect to the engine diameter. If a small installation space is available, as is required, for example, in vehicle construction, such comparatively cost-effective, but large disc rotor motors are unsuitable.
    The invention is therefore based on the task of structurally changing a pancake motor of the type described above so that, despite ferrite magnets on the rotor, a high power and torque density achieved and also small motor dimensions can be maintained to allow installation in a confined space , In addition, the pancake motor should have a low weight.
    The invention achieves this object by virtue of the fact that the stator teeth each end in a tooth end adjoining their tooth neck from a soft magnetic powder composite material, which end of the tooth widens in its cross-sectional area relative to the tooth neck.
    Ends the stator teeth each in a subsequent to the tooth neck tooth end of a soft magnetic powder composite material, the tooth end widens in relation to the tooth neck in its cross-sectional area, despite a rotor with ferrite magnet an optimum in terms of size of the disc rotor motor and also in terms of power and torque density being found. Thus, according to the invention, it is possible for the first time to be able to advance even with ferrite magnets into the class of pancake motors which, according to the prior art, are achieved exclusively by rotors with permanent magnets made of rare earths. Because of the stator teeth, which expand toward the end as well as through the special material (soft magnetic powder compound material) of the tooth end, the permanent magnetic flux of the ferrite magnets can be reliably and with low loss introduced into the tooth neck and thus into the stator - even if in the optimized case the power and torque density the ferrite magnets compared to the tooth neck forced as a considerably larger cross-sectional area must have. The tooth form according to the invention therefore explicitly leads to the motor concept of disc rotor motors with ferrite magnets to a compact and weight-reduced design with high power and torque densities and high efficiency. Thus, an unknown for such a pancake motor application in the automotive industry can open.
    In general, it is mentioned that SMC ("soft magnetic composites") can be particularly suitable as a soft magnetic powder composite material. Surprisingly, it was found that the opposite optimization parameters of weight or size and power and torque density find an optimum when the quotient of the smallest cross-sectional area of the tooth end and the largest cross-sectional area of the tooth neck is greater than 2. In addition, this is an easy-to-handle design rule for this disc rotor motor given.
    If the tooth neck and tooth end consist of the same soft magnetic powder composite material, the manufacture of the stator can be simplified. In particular, this SMC may be suitable as a soft magnetic powder composite material.
    Magnetic losses can be further reduced if the tooth neck and tooth end, made in one, form a one-piece component of the stator. In addition, this can lead to simplified conditions in the assembly of the stator, by only after a winding of the one-piece stator tooth this is firmly connected to the magnetically conductive stator yoke of the stator, for example by material and / or interlocking measures between the two parts to be joined.
    As an alternative to the integral nature of the stator tooth, it is also conceivable for the tooth end to be placed on the tooth neck and thus firmly connected in order to allow winding of the tooth neck.
    This option of winding the stator teeth before the end of the tooth is tightly connected to the neck of the tooth also makes it possible to construct the stator structurally. Namely, the tooth neck and a one-piece or multi-part stator yoke of the stator can be made into a one-piece component, thereby facilitating the assembly of the disc rotor motor. In addition, the stator yoke and the tooth neck can therefore have identical magnetic characteristics due to the same soft magnetic powder composite material, which can further facilitate the construction of the disc rotor motor.
    A comparatively high power and torque density on the pancake motor can be achieved if the stator teeth and the ferrite magnets are arranged concentrically in the edge region of the stator or rotor.
    If the rotor has a carrier disk with openings in the region of the ferrite magnets, an increased mass of ferrite magnets can be fastened to the rotor and the rotor can nevertheless be made slender. In particular, the use of stainless steel can prove itself for the carrier disk to mechanically stable store a variety of ferrite magnets. A sturdy pancake motor can result.
    An increased number of ferrite magnets can be provided on the carrier disk in a structurally simple manner, if ever a first ferrite magnet is inserted into an opening in the carrier disk and is covered on both sides by a respective second ferrite magnet resting on the carrier disk. This can provide not only an improvement in the power and torque density of the pancake motor for a reduced diameter of the rotor and thus further reduced dimensions of the pancake motor.
    If the openings in the carrier disk have a step-shaped opening edge on both sides, the fixed connection of the ferrite magnets to the carrier disk can be made mechanically stronger if the second ferrite magnets project into the stepped opening edge in alignment. That is, not only forms a positive connection between the first ferrite magnet inserted into the opening and the carrier disk. In addition, the second ferrite magnets can form a positive connection with the carrier disk via the stepped opening edge. A particularly resilient and stable rotor can thus be created, which in turn the stability of the disc rotor motor is further increased.
    The formation of eddy currents in the region of the openings of the carrier disk can be prevented if the carrier disk has slots in the edge region. This can, inter alia, avoid demagnetization of the ferrite magnets, and increase the stability of the pancake motor.
    If the slots form between T-shaped webs of the carrier disk, between which webs are the openings of the carrier disk for the ferrite magnets, a carrier disk in the form of a slotted spoke wheel can be created in a structurally simple manner. In addition to a weight reduction, this construction can also lead to advantageous magnetic conditions and increase the efficiency and the power and torque density of the pancake motor.
    The carrier disk mechanically loaded with the ferrite magnets can have an encircling groove on the front side, in which a reinforcing element is provided at least partially. The reinforcing element encircling the support disk can especially counteract deformations on the edge-side webs, with a bandage having proven itself here. An increased stability of the pancake motor can thus be assumed.
    To save weight, the reinforcing element may comprise at least one fiber. In addition, this can avoid a short circuit of the separated by slots edge preparation surface of the support disk and thus has no adverse effects on the efficiency and the power and torque density of the disc rotor motor. Fibers made of glass or carbon material can prove their worth.
    A comparatively high power and torque density on the pancake motor can be achieved if a stator is provided on each side of the rotor.
    The constructive design of the pancake motor can be simplified if the rotor has a magnetically conductive carrier disk on which the ferrite magnets are fixed over the entire surface, wherein the stator provided on one side to the rotor adjacent to the side of the carrier disk with the ferrite magnet via the axial gap. Compared with a two-sided such a one-sided pancake motor can form the magnetic inference through the support disk - thus the axial dimensions of the pancake motor can be significantly reduced by not using a second stator. In addition, this embodiment can be distinguished by its cost advantage.
    The efficiency and the power and torque density of the pancake motor can be increased, in which the stator has a magnetically conductive stator yoke and a heat conductor having an increased thermal conductivity compared to the stator yoke, via a recess or opening of the stator yoke on the coil of a wound tooth neck is applied. Thus, namely, the cooling of the winding can be improved, which cooling can suffer from the coil ends off the tooth ends.
    This cooling can be further improved if the heat conductor consists of aluminum or one of its alloys.
    In the figures, for example, the subject invention is illustrated in more detail with reference to several embodiments. Show it
    1 is a three-dimensional view of a half-cut double-sided disc rotor motor according to a first embodiment,
    2 is a torn-off and enlarged view of FIG. 1,
    3 is a plan view of a stator of the pancake motor of FIG.
    4 is a plan view of the rotor of the pancake motor of FIG.
    5 is a three-dimensional view of a half-cut one-sided pancake motor according to a second embodiment,
    6 is a torn off and enlarged view of FIG. 5,
    7 shows an alternative embodiment to a stator with a heat conductor, and FIG. 8 shows an alternative embodiment to a stator with respect to its stator tooth and stator yoke.
    In the embodiment shown in FIG. 1, a double-disc motor 1 is shown, which has a rotor 2 between two stators 3, 4 of equal design. The rotor 2 and the stators 3, 4 are oriented parallel to each other and spaced from each other by an axial gap 5. As can be seen from FIGS. 1, 2 and 4, the rotor 2 has a disk-shaped form, essentially shaped by its carrier disk 6. On the carrier disk 6 exclusively ferrite magnets 7, 8 are provided to form permanent magnet excited torques forming pole 9. It is also conceivable that these poles 9 contribute to the formation of force, for example, serve for contactless mounting of the rotor 2, which has not been shown in detail.
    Of the two identically formed stators 3 and 4, a stator yoke 10 is shown in FIG. 1, which ends in a plurality of parallel stator teeth 11. The stator teeth 11 and the tooth necks 12 are wound with coils 13 of a stator winding 14, which is preferably three-stranded (U, V, W) is formed, which was not set closer. As can be seen in comparison to FIGS. 3 and 4 and also to be provided in general, the maximum sum of the cross-sectional area AH of the tooth necks 12 is smaller than the sum of the pole faces which each result from the cross-sectional areas AF of the associated ferrite magnets 7, 8. Therefore, the ferrite magnets 7, 8 are clearly beyond the tooth necks 12 of the stators 3, 4 because the reduced energy density of the ferrite magnets 7, 8 must be compensated for - according to the invention, only the ferrite magnets 7, 8 should have the same power and torque density on the pancake motor 1 enable. Despite formation of the tooth neck 12 of the stator 3, 4 of a soft magnetic powder composite material, preferably SMC, it requires, as known from the prior art, a considerable size of the pancake motor 1 - namely in its diameter. In order to reduce this disadvantage, which occurs in particular in a confined space in the automotive industry, the stator teeth 11 each terminate in a subsequent to its tooth neck 12 tooth end 15 whose cross-sectional area AE increases relative to the cross-sectional area AH of the dental neck 12. This in combination with the construction of the tooth end 15 of a soft magnetic powder composite material, preferably SMC -gleichwie the tooth neck 12-, opens up further options for optimizing or reducing the size of the disc rotor motor 1. Namely, the special material of the tooth end 15 allows a three-dimensional magnetic flux guidance , so that the stator tooth 11 can be matched to the size of the ferrite magnets 7, 8 and thus an option for further optimization or reduction of the size of the pancake motor 1 results. Thus, a pancake motor 1 is provided which, despite the exclusive use of ferrite magnets 7, 8 in the rotor 2 has a high power and torque density and yet can be kept small in size. Cost-intensive permanent magnets made of rare earths can be dispensed with. The cost-effective disc rotor motor 1 according to the invention can therefore be used even in the automotive industry, where usually a confined space is available.
    The quotient of the largest cross-sectional area AE of the tooth end 15 and the smallest cross-sectional area AH of the tooth neck 12 is greater than 2, ie (AE / AH)> 2. Thus, according to the figures 2 and 3, a cylindrical shape of the neck 12 can be seen, followed by a tooth end 15 with an equally cylindrical shape. This measure on the one hand ensures high efficiency or high power and torque densities and on the other hand for smallest dimensions on the disc rotor motor 1. In general, it is mentioned that between tooth neck 12 and tooth end 15 a positive connection is conceivable, but this has not been shown in detail.
    As can be seen according to Figures 1 and 2, the tooth end 15 is placed on the tooth neck 12 and connected to this materially. A positive connection, alternatively or in addition, is also conceivable, which has not been shown in detail. The 3-dimensional flux guide of the tooth end 15 thus connects with low loss to the tooth neck 12 and thus ensures high power and torque densities.
    As shown in FIG. 3, the tooth neck 12 and the one-piece stator yoke 10 of the stator 3, 4 form a one-piece component 16, which minimizes losses in the magnetic flux guidance. But it is also conceivable that the stator yoke 10 is executed segmented, so as to meet the technical requirements of the pressing tools.
    Stator teeth 11 and ferrite magnets 7, 8 are arranged concentrically in the edge region 19, 20 of the stator 3, 4 or rotor 2, as can be seen in Figures 1 to 4. Thus, the pancake motor 1 can generate a high torque, which is additionally reinforced by the two-sided arrangement of a respective stator 3, 4 to the central rotor 2.
    High speeds, the rotor 2 record without deformation by its support plate 6 is made of stainless steel. In addition, this carrier disk has 6 openings 17, one of which in Fig. 4 can be seen in its entirety by no ferrite magnets 7 and 8 of the rotor 2 are shown there. An attenuation of the magnetic flux due to the support disk 6 can be avoided. In addition, a stacking of the ferrite magnets 7 and 8 is possible through these openings 17. Thus, a first ferrite magnet 8 is inserted accurately into the opening 17 of the support disk 6. This first ferrite magnet 8 is covered on both sides by one each resting on the support plate 6 second ferrite 7. In the region of an opening 17 so that three ferrite magnets 7, 8 are provided, which ensures per permanent magnetic pole 9, a high magnetic flux.
    In addition, the openings 17 in the carrier disc 6 on both sides of a stepped opening edge 18, in which the second ferrite magnets 7 projecting in alignment, which significantly increases the fixed connection with the outer ferrite 7.
    Further, according to FIG. 4, slits 21 can be seen in the edge region 20 of the carrier disk 6 in order to reduce eddy currents in and thus losses in the carrier disk 6. These slots 21 are formed between T-shaped webs 22 of the support disk 6, which also connect to simplify the construction of the openings 17 of the carrier disk 6 for the ferrite magnets 7, 8.
    For the mechanical reinforcement of the carrier disk 6, this has a peripheral groove 23 on the end face into which a reinforcing element 24 is inserted. This reinforcing element 24 acts as a bandage and is reinforced in the circumferential direction of fibers 25 made of a glass or carbon material, which guarantees a high stability and vibration resistance of the rotor 2 and the pancake motor 1.
    The pancake motor 26 shown in FIGS. 5 and 6 as a second exemplary embodiment differs from the pancake motor 1 illustrated in FIGS. 1 to 4 essentially by its one-sided motor construction. This difference is manifested essentially in constructive changes on the rotor 27. Thus, it can be seen in the rotor 27 that a ferrite magnet 7 is fastened to its carrier disk 6 per magnetic pole 9. The support disk 6 is magnetically conductive and has no openings for concentrating the magnetic flux in the region of the ferrite magnets 7. Thus, the ferrite magnets 7 are fixed over the entire surface of the support plate 6, preferably cohesively. Again, between the stator 3 and rotor 27, an axial gap 5 is provided, which separates them from each other. The stator 3 of the pancake motor 26 is constructed identically to the stator 3 of the pancake motor 1, as can be seen from a comparison of Figures 1 and 5. The coils 13 of the stator winding 14, not shown on the left side of the cut-away disk motor 26, serve for the purpose of clarity and a better view of the stator teeth 11. The disk motor 26 according to FIGS. 5 and 6 permits extremely compact electrical operation due to its comparatively short overall length drives.
    In general it is mentioned that for all embodiments it is not mandatory that all stator teeth 11 must be wound.
    Referring to FIG. 7, an alternative embodiment to a stator 28 is shown which, unlike the stators of FIGS. 1, 2, 3, 5 and 6, has an opening 29 for a heat conductor 30. This opening 29 is provided in the stator yoke 10 of the stator, and allows the heat conductor 30 to be connected to the bottom of the coil 13 of the winding of the stator tooth 11 to dissipate the heat loss of the coil 13 improved. The cooling of the coil 13 can namely suffer from the covering effect of the tooth end. The efficiency and the power and torque density of the disc rotor motor 1, 26 is thus increased. In addition, the heat conductor 30, which has an increased thermal conductivity to the stator yoke 10, partially adjoins the coil 13 laterally, which further improves the cooling, but does not hinder the interconnection of the coils 13. Heat conductor 30 is made of aluminum but can also have any other heat-conducting material. In addition, the heat conductor 30 can serve as a carrier or housing for the stator 28, in which this the Statorjoch, as shown in Fig. 7, surrounds. A sturdy pancake motor 1,26 is thus created.
    FIG. 8 shows a further alternative embodiment to a stator 31 with regard to its stator tooth 11 and stator yoke 10. The tooth neck 12 and tooth end 15, made in one, form an integral component 32 of the stator 31. The component 32 thus completely forms the stator tooth 11. This component 32 is non-positively and / or positively connected to the magnetically conductive stator yoke 10 of the stator 31. Thus, magnetic losses occur between the tooth neck 12 and the tooth end 15 reduced.
    权利要求:
    Claims (18)
    [1]
    1. Disc rotor motor having at least one stator (3, 4, 28, 31), the at least one electric stator winding (14) and stator teeth (11) forming a tooth neck (12) made of a soft magnetic powder composite material, and having at least one disk-shaped rotor (2, 27), the permanent magnetic pole (9) formed exclusively by ferrite magnets (7, 8) at least for torque generation, said rotor (2, 27) and stator (3, 4, 28, 31) oriented parallel to each other and by an axial gap (5) are spaced from each other, characterized in that the stator teeth (11) each end in a tooth neck (12) adjoining the tooth end (15) of a soft magnetic powder composite material, which tooth end (15) opposite the tooth neck ( 12) in its cross-sectional area (AE) extended.
    [2]
    2. pancake motor according to claim 1, characterized in that the quotient of the largest cross-sectional area (AE) of the tooth end (15) and the smallest cross-sectional area (AH) of the tooth neck (12) is greater than 2.
    [3]
    3. pancake motor according to claim 1 or 2, characterized in that the tooth neck (12) and tooth end (15) from the same soft magnetic powder composite material, in particular SMC exist.
    [4]
    4. pancake motor according to claim 3, characterized in that the tooth neck (12) and tooth end (15), in one manufactured, a one-piece component (32) of the stator (31) form, which component (32) with a magnetically conductive stator yoke (10 ) of the stator (31) is firmly connected.
    [5]
    5. pancake motor according to claim 1, 2 or 3, characterized in that the tooth end (15) on the tooth neck (12) placed and thus firmly connected.
    [6]
    6. pancake motor according to claim 5, characterized in that the tooth neck (12) and a one- or multi-part Statorjoch (10) of the stator (3, 4, 28), in one manufactured, a one-piece component (16) form.
    [7]
    7. pancake motor according to one of claims 1 to 6, characterized in that the stator teeth (11) and the ferrite magnets (7, 8) concentrically in the edge region (19, 20) of the stator (3, 4, 28, 31) and rotor (2, 27) are arranged.
    [8]
    8. pancake motor according to one of claims 1 to 7, characterized in that the rotor (2), in particular made of stainless steel, carrier disc (6) having openings (17) in the region of the ferrite magnets.
    [9]
    9. pancake motor according to claim 8, characterized in that in each case a first ferrite magnet (8) in an opening (17) of the carrier disc (6) is inserted and covered on both sides by one of the carrier disc (6) resting second ferrite magnet (7).
    [10]
    10. pancake motor according to claim 9, characterized in that the openings (17) in the carrier disc (6) on both sides of a stepped opening edge (18), in which the second ferrite magnets (7) projecting in alignment.
    [11]
    11. pancake motor according to claim 8, 9 or 10, characterized in that the carrier disc (6) in the edge region slits (21).
    [12]
    12. pancake motor according to claim 11, characterized in that the slots (21) between T-shaped webs (22) of the carrier disc (6) form, between which webs (22), the openings (17) of the carrier disc (6) the ferrite magnets (8) are located.
    [13]
    13. pancake motor according to one of claims 8 to 12, characterized in that the carrier disc (6) frontally a circumferential groove (23), in which a reinforcing element (24), in particular a bandage, at least partially provided.
    [14]
    14. pancake motor according to claim 13, characterized in that the reinforcing element (24) at least one fiber (25), in particular made of glass or carbon material having.
    [15]
    15. pancake motor according to one of claims 8 to 14, characterized in that on both sides of the rotor (2) each have a stator (3, 4, 28, 31) is provided.
    [16]
    16. pancake motor according to one of claims 1 to 7, characterized in that the rotor (27) has a magnetically conductive carrier disk (6) on which the ferrite magnets (7) are fixed over the entire surface, wherein the one-sided to the rotor (27) provided stator (3, 28, 31) over the axial gap (5) on the side of the carrier disc (6) with the ferrite magnets (7) adjacent.
    [17]
    17. pancake motor according to one of claims 1 to 16, characterized in that the stator (28) has a magnetically conductive stator yoke (10) and compared to the stator yoke (10) has an increased thermal conductivity heat conductor (30), which has a recess or opening (29) of the stator yoke (10) abuts the coil (13) of a wound tooth neck (12).
    [18]
    18. pancake motor according to claim 17, characterized in that the heat conductor (30) consists of aluminum or one of its alloys.
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    CN109194082B|2018-09-30|2020-07-07|沈阳工业大学|Amorphous alloy axial flux motor with wide field weakening speed expansion and low rotor loss|
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    法律状态:
    2021-12-15| PC| Change of the owner|Owner name: MIBA SINTER AUSTRIA GMBH, AT Effective date: 20211022 |
    优先权:
    申请号 | 申请日 | 专利标题
    ATA50510/2013A|AT514709B1|2013-08-16|2013-08-16|Pancake motor|ATA50510/2013A| AT514709B1|2013-08-16|2013-08-16|Pancake motor|
    DE201410111234| DE102014111234A1|2013-08-16|2014-08-07|Pancake motor|
    US14/460,854| US10651695B2|2013-08-16|2014-08-15|Disc rotor motor|
    CN201410406722.7A| CN104377846B|2013-08-16|2014-08-18|Disk rotor motor|
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