阅读说明：本技术 同步电机 (Synchronous machine ) 是由 J·G·米林格 于 2018-04-16 设计创作，主要内容包括：本发明涉及一种用于电动工具的同步电机。所述同步电机(10)包括管状转子(11),其被磁化成具有周向极性交变。同步电机(10)进一步包括铁磁材料的管状无槽定子磁轭(12)。管状转子(11)被磁化成具有两对周向极性交变,并且定子(13)包括三个同心缠绕线圈(14)。所述三个同心缠绕线圈(14)以不重叠的方式组装在管状定子磁轭(12)内侧,以形成集中式电机绕组。(The present invention relates to a synchronous motor for an electric tool. The synchronous machine (10) comprises a tubular rotor (11) magnetized with circumferential polarity alternation. The synchronous machine (10) further comprises a tubular slotless stator yoke (12) of ferromagnetic material. The tubular rotor (11) is magnetized with two pairs of circumferentially alternating polarities and the stator (13) comprises three concentrically wound coils (14). The three concentrically wound coils (14) are assembled inside the tubular stator yoke (12) in a non-overlapping manner to form a concentrated motor winding.)

1. A synchronous motor (10) for a power tool, comprising:

-a tubular rotor (11) magnetized with circumferential polarity alternation;

-a tubular slotless stator yoke (12) of ferromagnetic material, characterized in that,

-magnetizing the tubular rotor (11) with two pairs of circumferential polarity alternations, and

-the stator (13) comprises three concentrically wound coils (14), wherein the three concentrically wound coils (14) are assembled inside the tubular stator yoke (12) in a non-overlapping manner to form a concentrated motor winding.

2. The synchronous machine (10) as claimed in claim 1, wherein the three concentrically wound coils (14) are symmetrically distributed inside the stator yoke (12).

3. The synchronous machine (10) according to any of claims 1-2, wherein the three concentrically wound coils (14) are arranged in a self-supporting manner.

4. A synchronous machine (10) as claimed in any of claims 1 to 3, wherein the diameter of the tubular rotor (11) is more than 50% of the outer diameter of the tubular slotless stator yoke (12).

5. The synchronous machine (10) as claimed in any of claims 1 to 4, wherein the three concentrically wound coils (14) are surrounded by an insulating material (15).

6. The synchronous machine (10) according to any of claims 1-5, wherein the tubular slotless stator yoke (12) comprises a stack of metal plates.

7. The synchronous machine (10) as claimed in claim 5, wherein said three concentrically wound coils (14) are glued on said insulating material (15).

8. The synchronous machine (10) according to any of claims 1-7, wherein the tubular slotless stator yoke (12) is divided into three identical sections.

9. The synchronous machine (10) of claim 8, wherein the three concentrically wound coils (14) are glued inside each stator yoke segment.

10. The synchronous machine (10) according to any of claims 1-9, wherein the three concentrically wound coils (14) are wound on evenly distributed arbours (16).

11. The synchronous machine (10) according to claim 10, wherein the evenly distributed arbour shafts (16) are glued on the insulating material (15).

Technical Field

The present invention relates to a synchronous machine. In particular, the present invention relates to a synchronous motor for a power tool, which has a low manufacturing complexity.

Background

Compared with a slotted permanent magnet synchronous motor, the slotless permanent magnet synchronous motor can operate at a high rotating speed. High speed operation not only achieves higher efficiency and power density, but also achieves weight savings. Therefore, slotless permanent magnet motors are preferred in industrial power tools.

A conventional method of manufacturing a slotless electric machine for such applications is to use a two-pole rotor inside a tubular stator yoke that carries inside it a three-phase winding containing three coils. A commonly used winding configuration is the so-called "overlapping winding technique", which is characterized in that the winding ends overlap in a complex manner.

In particular, the combination of overlapping winding technology and slotless stator design results in a very complex assembly process.

Accordingly, there is a need for an improved slotless motor for use in a power tool.

Disclosure of Invention

It is an object of the present invention to provide an improved slotless motor for use in a power tool.

According to one aspect of the invention, the object is achieved by a synchronous motor for a power tool. The synchronous machine comprises a tubular rotor magnetized with circumferential polarity alternation. The synchronous machine further comprises a tubular slotless stator yoke of ferromagnetic material. The tubular rotor is magnetized with two pairs of circumferentially alternating polarities and the stator comprises three concentrically wound coils. The three concentrically wound coils are assembled inside the tubular stator yoke in a non-overlapping manner to form a concentrated motor winding.

An advantage of exemplary embodiments of the present invention is that manufacturing costs may be significantly reduced since three concentrically wound coils may be individually inserted in a non-overlapping manner (referred to as "concentrated winding technology").

By using the so-called "concentrated winding technique" characterized by non-overlapping winding ends, the assembly process can be greatly simplified, thereby improving quality and reducing costs.

However, such winding techniques often result in reduced performance and unacceptable levels of vibration and noise. This is the case for a two-pole rotor in combination with a stator using the concentrated winding technique described.

One aspect of the present invention relates to a design for a permanent magnet synchronous machine that employs low cost concentrated winding technology, but maintains performance in terms of vibration, noise, and efficiency.

Drawings

The invention will now be described in more detail with reference to the accompanying drawings, in which:

fig. 1 shows a cross section of a synchronous machine 10 according to an exemplary embodiment of the invention.

Fig. 2 shows a view of one concentrically wound coil 14.

Detailed Description

To reduce the manufacturing cost of the stator, the inventors have realized that non-overlapping concentrated winding techniques are advantageous. However, concentrated motor windings can add higher harmonic content, resulting in increased losses, vibration, and noise.

Conventional two-pole rotors have been tested in conjunction with stators that deploy concentrated windings containing three coils. In addition to the increased losses, unacceptable levels of vibration, radial force and noise were also detected.

The manufacture of a two-pole rotor is relatively simple because a plurality of annular anisotropic magnets can be assembled onto the shaft before machining to the correct dimensions.

However, a four-pole rotor requires at least four outer peripheral sections for one ring of magnets. The complexity and cost of such rotors is much higher, but the cross-sectional geometry can be re-optimized with increased torque performance up to 80%.

However, the overlapping windings designed for four poles, which contain six windings, are very complicated to assemble. Therefore, the quality is further reduced, resulting in an increase in cost.

The present invention relates to the use of three concentrically wound coils assembled in a non-overlapping arrangement to operate a rotor with two pairs of circumferential polarities alternating. This is possible because three concentrically wound coils produce multiple harmonic components, one of which is a quadrupole magnetic field. The disadvantage of this technique is a 30% loss in torque performance compared to overlapping stator windings. However, the concentrated winding technique enables the winding tips to be significantly shortened, thereby reducing the motor size or increasing the effective motor length, thereby achieving a return on torque/volume ratio. Furthermore, the level of vibration, noise and radial forces of the combination of three concentrically wound coils and a rotor with two pairs of circumferentially alternating polarities is sufficiently low from the point of view of the power tool.

Fig. 1 shows an exemplary embodiment of a synchronous motor 10 for a power tool according to the present invention. As can be seen in fig. 1, the synchronous machine 10 comprises a tubular rotor 11 which is magnetized with circumferential polarity alternation. Furthermore, the synchronous machine 10 comprises a tubular slotless stator yoke 12 made of ferromagnetic material. The tubular rotor 11 is magnetized with two pairs of circumferential polarity alternations. The synchronous machine 10 further comprises a stator 13 having three concentrically wound coils 14, wherein the three concentrically wound coils 14 are assembled inside the tubular stator yoke 12 in a non-overlapping manner to form a concentrated machine winding.

According to an exemplary embodiment, the tubular rotor 11 is made of anisotropic rare earth magnets (magnets with preferred magnetization directions) to maximize motor torque performance. According to one exemplary embodiment, two pairs of circumferential polarity alternations require the use of at least four circumferential anisotropic magnet pieces. According to another exemplary embodiment, two pairs of circumferential polarity alternations require the use of a multiple of four (e.g., eight) circumferential anisotropic magnet pieces.

According to one exemplary embodiment, the non-overlapping concentrated windings are characterized by a coil arrangement in which each coil can be inserted separately (as compared to a conventional full pitch overlapping winding in an opposed manner), thereby greatly simplifying the assembly process. According to another exemplary embodiment of the synchronous machine 10, three concentrically wound coils 14 are symmetrically distributed inside the stator yoke 12.

According to an exemplary embodiment, the tubular slotless stator yoke 12 is made of so-called "electrical steel" to maximize torque performance. According to another exemplary embodiment, the tubular slotless stator yoke 12 is made of a plurality of thin metal plates axially stacked to form a tubular stator yoke.

In another exemplary embodiment of the synchronous machine 10, three concentrically wound coils 14 are arranged in a self-supporting manner. In an exemplary embodiment of the synchronous machine 10, the three concentrically wound coils 14 are secured by vacuum impregnation of synthetic resin and then cured to a final shape and position.

In another exemplary embodiment of the synchronous machine 10, the diameter of the tubular rotor 11 is greater than 50% of the outer diameter of the tubular slotless stator yoke 12. One advantage of this embodiment is improved efficiency.

Fig. 2 shows a view of one of the concentrically wound coils 14. In an exemplary embodiment of the synchronous machine 10, three concentrically wound coils 14 are surrounded by an insulating material 15. According to an exemplary embodiment of the synchronous machine 10, the insulating material 15 is a polyester-based electrically insulating paperboard to provide mechanical support during assembly of the windings. Another advantage of polyester based electrically insulating paperboard is that it meets the electrical insulation requirements.

Fig. 2 further illustrates the spool 16. In another exemplary embodiment of the synchronous machine 10, three concentrically wound coils 14 are wound on a bobbin 16. The advantage of winding three coils 14 on the bobbin 16 is that the bobbin not only simplifies the manufacture of the coils, but also simplifies the assembly of the windings.

In yet another exemplary embodiment of the synchronous machine 10, the bobbin 16 is glued on the insulating material 15. The advantage of gluing the bobbin 16 to the insulating material 15 is that not only the manufacture of the coil is simplified, but also the assembly of the windings.

In another exemplary embodiment of the synchronous machine 10, the tubular slotless stator yoke 12 comprises a stack of axially stacked metal plates. In another exemplary embodiment of the synchronous machine 10, the tubular slotless stator yoke 12 comprises a plurality of axially stacked metal plate rings that are mechanically supported by a peripheral weld. In an exemplary embodiment of the synchronous machine 10, the peripheral weld seams are symmetrically distributed.

According to another exemplary embodiment of the synchronous machine 10, three concentrically wound coils 14 are glued on an insulating material 15. One advantage of this embodiment is that it makes it possible to simplify the mass production of concentrically wound coils 14.

In another exemplary embodiment of the synchronous machine 10, the tubular slotless stator yoke 12 is divided into three identical sections. One advantage of such a modular assembly is that it can simplify automated manufacturing of the same.

In another exemplary embodiment of the synchronous machine 10, three concentrically wound coils 14 are glued on the inside of each stator yoke section.