阅读说明：本技术 无刷电动机 (Brushless motor ) 是由 大堀龙 盐田直树 杉山友康 早田圣基 于 2018-05-01 设计创作，主要内容包括：无刷电动机(1)具有具备定子芯(5)和绕组(6)的定子(2)、具备磁铁(13)的转子(3)、以及检测转子(3)的旋转位置的磁传感器(18)。转子(3)具有偏斜构造,对磁铁(13)实施了偏斜磁化。磁铁(13)具有伸出部(14),磁传感器(18)与伸出部(14)的轴向端面(20)相向地配置。磁铁(13)的偏斜角在将磁传感器(18)配置在绕组励磁的影响小的最佳位置的状态下,与基于Δ接线、正弦波驱动等电动机规格的传感器配置的角度偏差相匹配地设定。(A brushless motor (1) is provided with a stator (2) having a stator core (5) and a winding (6), a rotor (3) having a magnet (13), and a magnetic sensor (18) for detecting the rotational position of the rotor (3). The rotor (3) has a skew structure and performs skew magnetization on the magnet (13). The magnet (13) has an extension portion (14), and the magnetic sensor (18) is disposed so as to face an axial end surface (20) of the extension portion (14). The offset angle of the magnet (13) is set so as to match the angular deviation of the sensor arrangement based on the motor specifications such as delta connection and sine wave drive, in a state where the magnetic sensor (18) is arranged at an optimum position where the influence of the winding excitation is small.)

1. A brushless motor has:

a stator including a stator core and a winding wound around the stator core;

a rotor disposed radially inside the stator and including a magnet; and

a magnetic sensor that detects a rotational position of the rotor by detecting a magnetic force of the magnet,

it is characterized in that the preparation method is characterized in that,

the rotor has a skew configuration in which switching positions of magnetic poles of the magnets are shifted in a rotational direction along an axial direction,

the magnet has a protruding portion that does not face the stator core but extends in an axial direction from an axial end of the stator core,

the magnetic sensor is disposed to face an axial end surface of the protruding portion of the magnet.

2. The brushless motor of claim 1,

the winding has a winding thickening portion formed from an axial end portion of the stator core toward an axial direction,

the protruding portion extends in the axial direction beyond the winding thickening portion, and is disposed closer to the magnetic sensor than the winding thickening portion.

3. The brushless motor according to claim 1 or 2,

the magnetic sensor is disposed at a distance in the axial direction from the magnet, and at least a part of the magnetic sensor is provided so as to overlap with an axial end face of the protruding portion facing the magnet.

4. The brushless motor according to any one of claims 1 to 3,

when the position of the projecting portion side in the switching positions of the magnetic poles at both ends of the magnet is represented by P and the position on the opposite side of the projecting portion is represented by Q,

assuming that the axial dimension of the stator core is L, the skew angle of the magnet corresponding to the axial dimension of the stator core is θ T, and the axial dimension of the extension portion is OH, the skew angle θ R between P, Q indicating the skew angles of the entire magnet including the extension portion is represented by θ R ═ θ T + (θ T/L) × OH,

when the offset angle from the magnetic pole switching position Q to the magnetic pole center position M of the magnet is represented by θ M, the θ M is represented by θ T/2,

the offset angle thetax from the magnetic pole center position M to the magnetic pole switching position P is set to thetaR-thetaM according to the motor specification.

5. The brushless motor of claim 4,

the skew angle thetaX is set in a range of 0 DEG < theta.ltoreq.60 DEG (electrical angle).

Technical Field

The present invention relates to a brushless motor, and more particularly to a brushless motor of a so-called direct sensing type that directly senses magnetic flux of a rotor magnet without using a sensor magnet.

Background

Conventionally, a drive method is known in which, at the time of drive control of a brushless motor, the position of a rotor is detected by directly sensing magnetic flux of a rotor magnet without using a sensor magnet (for example, patent document 1). Such a driving manner is called direct sensing. Since the direct sensing type motor does not require a sensor magnet in the motor, the number of parts is reduced, and the size and cost of the device can be reduced. However, the direct sensing type motor has a problem that the sensing of the rotor position is easily hindered due to the influence of magnetic flux from the winding excitation. Therefore, in the conventional direct sensing type motor, in order to minimize the influence of the winding excitation, as shown in fig. 5(a), a sensor is usually disposed at a position farthest from the winding of the conducting phase to detect the switching of the magnetic pole.

The brushless motor 51 of fig. 5(a) includes a 2- pole rotor 52 and 6 phase windings 53(53Ua, Ub, 53Va, Vb, 53Wa, Wb). Three magnetic sensors 54 (54U, 54V, 54W) for detecting switching of the magnetic poles of the rotor 52 are provided corresponding to the three phases. Each magnetic sensor 54 is disposed at a position farthest from the winding 53 of the currently energized phase to detect switching of the magnetic pole. Fig. 5(b) is a timing chart showing a relationship between the time of magnetism detection by the magnetic sensor 54 and the energization timing of the winding 53. As is clear from fig. 5(a) and (b), the magnetic sensor 54 is configured to detect switching of the magnetic poles by the magnetic sensor 54W existing at the farthest position from the windings 53Ua and Ub of the U-phase when current is supplied to these windings.

Disclosure of Invention

Problems to be solved by the invention

However, in the direct sensing type motor, the sensor arrangement as shown in fig. 5 is an ideal position in which the influence of the excitation is minimized in the case of the Y-line-rectangular wave drive, but the sensor arrangement is deviated by 30 ° in the electrical angle from the ideal position in the case of the Δ -line or sine wave drive. Therefore, if the sensor is arranged in accordance with the connection state or the driving method, it is difficult to provide the sensor at a position where the sensor is originally intended to be provided in order to suppress the influence of the magnetic field flux. That is, for the reason of motor design, there is a problem that the sensor cannot be arranged at an ideal position which is less susceptible to the influence of the excitation of the winding.

Means for solving the problems

A brushless motor of the present invention includes: a stator including a stator core and a winding wound around the stator core; a rotor disposed radially inside the stator and including a magnet; and a magnetic sensor that detects a magnetic force of the magnet to detect a rotational position of the rotor, wherein the rotor has a skew structure in which a switching position of a magnetic pole of the magnet is shifted in a rotational direction along an axial direction, the magnet has a protruding portion that does not face the stator core and extends from an axial end portion of the stator core along the axial direction, and the magnetic sensor is disposed so as to face an axial end surface of the protruding portion of the magnet.

In the present invention, the magnetic sensor is disposed so as to face the axial end face of the extension portion of the magnet, and the magnetic sensor is axially spaced from the winding, whereby the influence of the winding excitation on the magnetic sensor is suppressed to a small extent. In addition, by using a rotor of a skew structure, it is possible to reduce cogging torque and set a skew angle in accordance with an angular deviation of sensor arrangement based on motor specifications. Thus, the magnetic sensor is arranged at an optimum position where the influence of the winding excitation is small, and the magnetic sensor is adapted to the specifications (Δ connection, sine wave drive, and the like) of the motor. As the skew structure of the rotor, a magnet magnetized obliquely or a stepped skew structure using a segmented magnet can be used.

In the brushless motor, the winding may have a winding thickening portion formed from an axial end portion of the stator core in an axial direction, and the protruding portion may be provided to extend in the axial direction beyond the winding thickening portion and may be disposed closer to the magnetic sensor than the winding thickening portion.

The magnetic sensor may be disposed at a distance in the axial direction from the magnet, and at least a part of the magnetic sensor may be disposed so as to overlap an axial end face of the protruding portion facing the magnet.

When the position of the projecting portion side in the switching positions of the magnetic poles at both ends of the magnet is P and the position on the opposite side to the projecting portion is Q, if the axial dimension of the stator core is L, the skew angle of the magnet corresponding to the axial dimension of the stator core is θ T, and the axial dimension of the projecting portion is OH, the skew angle θ R between the P, Q indicating the skew angles of the entire magnet including the projecting portion is represented by θ R ═ θ T + (θ T/L) × OH. When θ M is a skew angle from the magnetic pole switching position Q to the magnetic pole center position M of the magnet, θ M is represented by θ T/2. In this case, the skew angle θ X from the magnetic pole center position M to the magnetic pole switching position P may be set to θ R — θ M according to the motor specification. In this case, the skew angle θ X may also be set in a range of 0 ° < θ ≦ 60 ° (electrical angle).

ADVANTAGEOUS EFFECTS OF INVENTION

According to the brushless motor of the present invention, the magnetic sensor is disposed so as to face the axial end face of the protruding portion of the magnet, whereby the magnetic sensor can be separated from the winding in the axial direction, and the influence of the winding excitation on the magnetic sensor can be suppressed to a small extent. Further, by adopting a skew structure in which the switching position of the magnetic poles of the magnets is shifted in the rotational direction along the axial direction, the cogging torque can be reduced, and the skew angle can be set so as to match the angular deviation of the sensor arrangement according to the motor specification. Therefore, the magnetic sensor can be arranged at the optimum position in accordance with the specification of the motor. As a result, even when the magnetic sensor cannot be arranged at the optimum position in the rotation direction in consideration of design, the magnetic sensor can be arranged at the optimum position by adjusting the inclination angle.

Drawings

Fig. 1 is an explanatory diagram showing a structure of a brushless motor according to an embodiment of the present invention.

Fig. 2 is an explanatory diagram showing a relationship between the protrusion amount and the detection angle delay of the magnetic flux due to the influence of the winding excitation.

Fig. 3 is an explanatory diagram showing a positional relationship between the magnetic sensor and the magnet.

Fig. 4 is an explanatory diagram showing the arrangement of the magnetic sensor.

Fig. 5 is an explanatory diagram showing a conventional sensor arrangement in a brushless motor of the direct sensing system.

Detailed Description

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. An object of the following embodiments is to provide a brushless motor in which a magnetic sensor can be disposed at a position that is less susceptible to magnetic flux excited by a winding, regardless of the design specifications of the motor. Fig. 1 is an explanatory diagram showing a structure of a brushless motor 1 (hereinafter, simply referred to as a motor 1) as an embodiment of the present invention. The motor 1 is used as a power source of a sunroof device of an automobile, and is an inner rotor type brushless motor in which a stator 2 is disposed on an outer side and a rotor 3 is disposed on an inner side. In the motor 1, a direct sensing method is employed in which the magnetic flux of the rotor magnet is directly sensed to detect the position of the rotor.

The stator 2 includes a case 4, a stator core 5 fixed to the inner peripheral side of the case 4, and a 3-phase (U, V, W) winding (coil) 6 wound around the stator core 5. The stator core 5 has a structure in which a plurality of steel plates are stacked, and includes an annular yoke portion 7 and a plurality of teeth 8 projecting inward from the yoke portion 7. The winding 6 is wound around each tooth 8 with an insulator 9 interposed therebetween.

The rotor 3 is disposed inside the stator 2. The rotor 3 has a structure in which a rotating shaft 11, a rotor core 12, and a magnet 13 are coaxially arranged. A cylindrical rotor core 12 formed by stacking a plurality of steel plates is attached to the outer periphery of the rotating shaft 11. A magnet 13 is fixed to the outer periphery of the rotor core 12. The rotor 3 has a skew structure in which the switching positions of the magnetic poles of the magnets 13 are shifted in the rotational direction along the axial direction. The magnet 13 is obliquely magnetized so that the switching position of the magnetic pole is inclined with respect to the central axis in the axial direction. By adopting such a skew structure, in the motor 1, a reduction in cogging torque is achieved.

In the motor 1, one end side of the magnet 13 extends further in the axial direction than the axial end 5a of the stator core 5. That is, on one end side of the magnet 13, a protruding portion 14 extending in the axial direction from the axial end 5a of the stator core 5 is formed so as not to face the stator core 5. The protruding portion 14 extends beyond a winding thickening portion 15 formed at an axial end of the winding 6. The axial length (protrusion amount) OH of the protrusion 14 is larger than the axial dimension B (OH > B) of the winding thicken 15.

In the brushless motor that performs direct induction, a difference occurs in the detection position of the magnetic pole switching between the energization state and the non-energization state due to the influence of the magnetic flux of the winding excitation, and the detection angle tends to be delayed in the energization state compared to the non-energization state. Fig. 2 is an explanatory diagram showing a relationship between the protrusion OH and a detection angle delay of the magnetic flux (delay of switching detection of the magnetic pole) due to the influence of the winding excitation, where (a) shows when the current is 6A, and (b) shows when the current is 15A. According to the analysis of the inventors, it is found that the delay of the detection angle is smaller as the protrusion OH is larger, and the delay increase is larger as the protrusion OH is smaller than the dimension B of the winding thickening portion 15. Therefore, in the motor 1, the extension portion 14 is set to be larger than the winding thickening portion 15 (OH > B), and the influence of the winding excitation is suppressed to be small.

Bearings 16a and 16b are attached to both ends of the housing 4. The rotary shaft 11 is rotatably supported by the bearings 16a and 16 b. The case 4 is formed in a bottomed cylindrical shape, and a sensor bracket 17 is attached to an opening-side end portion of the case 4. A substrate 19 is mounted on the sensor bracket 17, and a magnetic sensor 18 using a hall element or the like is disposed on the substrate 19. The magnetic sensor 18 is a so-called surface-mount type sensor, and detects the magnetic force of the magnet 13 to detect the rotational position of the rotor 3.

The magnetic sensor 18 is disposed directly below the axial end surface 20 of the magnet 13 (the axial end surface of the extension portion 14) in the vertical direction so as to directly face the axial end surface 20. In this case, the magnetic sensor 18 does not need to face the entire axial end face 20 of the magnet 13. Fig. 3 is an explanatory diagram showing a positional relationship between the magnetic sensor 18 and the magnet 13. As shown by the one-dot chain line in fig. 3, the magnetic sensor 18 may be disposed so that a part thereof overlaps the axial end face 20 of the magnet 13. That is, at least a part of the magnetic sensor 18 is disposed at a position overlapping in the range of the width W in the radial direction of the axial end surface 20. Conversely, a state in which the magnetic sensor 18 and the magnet 13 do not overlap at all (the dashed line position in fig. 3) is not preferable because the magnetic flux of the magnet 13 may not be accurately captured.

In order to detect the commutation timing of each phase, 3 (18U, 18V, 18W) magnetic sensors 18 are provided for the U, V, W phases. Fig. 4 is an explanatory diagram showing the arrangement of the magnetic sensor 18. As shown in fig. 4, in the motor 1, 3 (18U, 18V, 18W) magnetic sensors 18 are arranged in the circumferential direction. The magnetic sensor 18 is provided at an ideal position similar to that of fig. 5, and is arranged to detect switching of the magnetic pole at a position farthest from the winding 6 of the phase currently energized. The magnet 13 is magnetized obliquely, and direct sensing can be performed in an optimum sensor arrangement state by adjusting the oblique angle even if the sensor arrangement is shifted by 30 ° from the ideal position in the motor 1 as in the case of Δ wiring or sine wave driving.

In the motor 1, the skew angle is set as follows. As shown in fig. 4, in the motor 1, the switching position S of the magnetic pole is formed obliquely with respect to the axial direction by the skew magnetization. When the position on the side of the extension portion 14 (one end side) in the switching positions S of the magnetic poles at both ends of the magnet 13 is P and the position on the opposite side (the other end side) to the extension portion 14 is Q, the skew angle θ R of the entire magnet 13 including the extension portion 14 becomes a skew angle between the points P, Q.

In this case, when the skew angle corresponding to the axial dimension (stator lamination thickness) L of the stator core 5 is θ T and the projection amount is OH, the skew angle θ R (skew angle between the points P to Q) of the motor 1 becomes θ R ═ θ T + (θ T/L) × OH.

On the other hand, the offset angle θ M at the magnetic pole center position M of the magnet 13 is θ M — θ T/2. Therefore, in the motor 1, a skew angle θ X (═ θ R — θ M) from the magnetic pole center position M to a point P (a portion of the magnetic pole switching position S that faces the magnetic sensor 18 at the axial end face 20) is set in accordance with a deviation in sensor arrangement based on motor specifications (Δ connection, sine wave drive, and the like).

For example, when the sensor arrangement is deviated from the ideal position by an electrical angle of 30 ° (mechanical angle 15 ° in the motor 1) by Δ connection, the value of "θ X ═ θ R — θ M" described above is set to the electrical angle of 30 °. Thus, the switching timing of the magnetic poles detected by the magnetic sensor 18 is adjusted by the electrical angle of 30 °, and the magnetic sensor 18 can be adapted to a Δ -wired motor in a state where it is arranged (fixed) at an optimum position. That is, by further adjusting the angle of the skew having the cogging-torque reduction effect, the drive control of the Δ -wired brushless motor can be performed in a state where the magnetic sensor 18 is disposed at an optimum position where the influence of the magnetic flux excited by the winding can be minimized. The angle adjustment by the skew can be performed in a range of at least 30 ° electrical angles (60 ° electrical angles as a whole) on the left and right sides in accordance with the rotation direction of the motor, with respect to the skew-free state.

As described above, in the motor 1 of the present invention, a surface-mount type sensor is used as the magnetic sensor 18, and is disposed to face the axial end face 20 of the magnet 13. In addition, first, the extension portion 14 is set larger than the winding thickening portion 15 (OH > B), and the magnetic sensor 18 is moved away from the winding 6 to suppress the influence of the winding excitation. That is, the influence of the winding excitation is reduced in the axial direction of the motor 1 by the extension portion 14.

The magnet 13 is magnetized obliquely, and the offset angle is set in accordance with the angular deviation of the sensor arrangement based on the motor specification, and the magnet sensor 18 is arranged at the optimum position in accordance with the motor specification. Thus, according to the design, even when the magnetic sensor 18 cannot be arranged at the optimum position in the rotation direction, the magnetic sensor 18 can be arranged at the optimum position by adjusting the inclination angle. That is, by the skew angle adjustment, the influence of the winding excitation is minimized in the rotational direction of the motor 1. In addition, by associating the excitation magnetic flux in the axial direction and the rotational direction, the influence of the winding excitation is minimized in the brushless motor of the direct sensing system, and the control accuracy can be improved.

The present invention is not limited to the above-described embodiments, and various modifications can be made without departing from the scope of the invention.

For example, in the above-described embodiments, the present invention is applied to the motor having the so-called SPM structure in which the magnet is arranged on the outer periphery of the rotor, but the structure of the motor is not limited to this. The present invention can also be applied to a motor of a so-called IPM structure in which a magnet is embedded in a rotor, for example. The inclination direction and angle of the skew can be set appropriately according to the motor specification.

As the deflection structure of the rotor 3, a stepped deflection in which the switching position of the magnetic poles is shifted stepwise in the rotational direction along the axial direction can be adopted. In this case, for example, in the case of the step skew using the segment magnets, a plurality of rows of segment magnets are arranged in the axial direction on the outer periphery of the rotor. In addition, a plurality of segment magnets are also arranged in each row in the rotational direction (circumferential direction). The magnets of each row adjacent in the axial direction are shifted in the rotational direction along the axial direction in the magnetic pole switching position. In the motor having such a step-skew structure, the skew angle θ R and the like in the present application are calculated by processing a line connecting the centers of the segment magnets in the axial direction as the "switching position S of the magnetic pole", and the skew angle adjustment described above is performed.

Industrial applicability

The brushless motor according to the present invention can be applied not only to a motor for a sunroof of an automobile but also to motors used in various vehicle-mounted motors such as a motor for a power window and a motor for a power-driven adjustable seat, home electric appliances such as an air conditioner, and the like.

Description of reference numerals

1 brushless motor 2 stator

3 rotor 4 casing

5 stator core 5a axial end portion

6 winding 7 yoke

8-tooth 9 insulator

11 rotating shaft 12 rotor core

13 magnet 14 extension

15 winding thickening part 16a, 16b bearing

17 sensor carrier 18 magnetic sensor

19 axial end face of substrate 20

51 brushless motor 52 rotor

53 winding

53Ua, Ub, 53Va, Vb, 53Wa, Wb phase winding

54 magnetic sensor

54U, 54V, 54W magnetic sensor

B axial dimension OH overhang of the coil upset

Switching position W magnet width of S magnetic pole

Switching position of magnetic pole on P-one end side

Switching position of magnetic pole on the other end side of Q

Center position of M magnetic pole

L axial dimension of stator core (stator lamination thickness)

Skew angle corresponding to theta T and stator lamination thickness

Skew angle at central position M of theta M magnetic pole

Skew angle of theta R magnet as a whole

Angle of deviation of θ X from magnetic pole center position M to point P