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EP-4738662-A1 - BRUSHLESS MOTOR, MANUFACTURING METHOD THEREFOR AND APPARATUS

EP4738662A1EP 4738662 A1EP4738662 A1EP 4738662A1EP-4738662-A1

Abstract

The present disclosure relates to a brushless motor, a manufacturing method therefor and an apparatus. The brushless motor comprises: at least one stator core (1), each stator core (1) comprising a plurality of tooth groups (11) which are spaced apart in a circumferential direction thereof, and the total number of the tooth groups (11) being Z ; a rotor (2), which can rotate relative to the stator core (1), the rotor (2) comprising a magnetic ring (21) having a pole number of P, and P being an even number; and at least two-phase wires (3), which are wound around the tooth groups (11) to form coils (31) on the tooth groups (11), the total number of phases of the wires (3) being X , each phase wire (3) having an independent first end and second end, for the same phase wire, the number of tooth groups (11) spaced between coils (31) on two adjacent tooth groups (11) being X -1, winding directions of the coils (31) on the two adjacent tooth groups (11) in the circumferential direction of the tooth groups (11) being opposite, and Z=P*X.

Inventors

  • ZHANG, PING
  • WU, Sin Hin
  • SUN, Xinglin
  • ZHOU, Huizhu
  • SUN, Yelin
  • LUO, Lanying

Assignees

  • Xuxin Technology (Shenzhen) Group Co., Ltd

Dates

Publication Date
20260506
Application Date
20240511

Claims (20)

  1. A brushless motor comprising: a stator core (1) comprising a plurality of tooth groups (11) arranged at intervals along a circumferential direction of the stator core (1), the total number of the tooth groups (11) being Z; a rotor (2) rotatable relative to the stator core (1) and comprising a magnetic ring (21) with P poles, P being an even number; and at least two phase wires (3) wound around the plurality of tooth groups (11) to form a respective one of a plurality of coils (31), the total number of the at least two phase wires (3) being X , and each phase wire (3) having a first end and a second end independent of each other; for the same phase wires (3), the number of tooth groups (11) spaced between the coils (31) on two adjacent tooth groups (11) being X- 1 , and the winding directions of the coils (31) on the two adjacent tooth groups (11) along the circumferential direction of the tooth groups (11) being opposite; where Z=P*X.
  2. The brushless motor of claim 1, wherein: at least one of the plurality of tooth groups (11) comprises a single tooth (11'), and the wire (3) is wound around the tooth (11') to form a coil (31) on the tooth (11'); and/or at least one of the plurality of tooth groups (11) comprises at least two teeth (11') arranged at intervals along the circumferential direction of the stator core (1), and the wire (3) is wound around the at least two teeth (11') to form a coil (31) on the at least two teeth (11').
  3. The brushless motor of claim 1, wherein each phase wire (3) is configured to be applied with an independent driving signal.
  4. The brushless motor of claim 1, wherein in a radial direction of the stator core (1), the winding direction of each coil (31) formed by at least two phase wires (3) is the same.
  5. The brushless motor of claim 4, wherein an initial winding position of each coil (31) formed by at least two phase wires (3) is located at a side away from the rotor (2).
  6. The brushless motor of claim 1, wherein in the radial direction of the stator core (1), both the first end and the second end of each of the at least two phase wires (3) are led out from the same side of the tooth group (11).
  7. The brushless motor of claim 1, wherein in the circumferential direction of the stator core (1), the first end and the second end of all of the at least two phase wires (3) are led out from a plurality of adjacent tooth groups (11).
  8. The brushless motor of claim 7, wherein: the winding directions of the coils (31) with the same sequence number along the circumferential direction of the tooth groups (11) starting from the first end are identical for the at least two phase wires (3); or for at least one group of adjacent two phase wires (3),the winding directions of the coils (31) with the same sequence number from the first end are opposite along the circumferential direction of the tooth groups (11).
  9. The brushless motor of claim 1, wherein the at least two phase wires (3) are sequentially wound along the circumferential direction of the stator core (1) in a sequence from a first phase to a X -th phase; the wires (3) each applied with a respective driving signal comprise an i -th phase wire (3) and a k -th phase wire (2), and a phase difference θ ik between the driving signal to the i -th phase wire (3) and the driving signal to the k -th phase wire (2) is denoted as θ ik = P 2 ∑ i k − 1 β X , where 1≤i<k≤X; and in the same stator core (1), a gap is present between the tooth group (11) of the x -th phase wire (3) and adjacent tooth groups (11) on both sides at their closest positions, and the gap has a central position in the circumferential direction of the stator core (1); in all gaps formed by the Z tooth groups (11), a central angle corresponding to an arc between the central position of the x -th phase wire (3) and an adjacent central position in the circumferential direction of the stator core (1) is β X , and a sector corresponding to β X comprises at least part of the tooth group (11) of the x-th phase wire (3).
  10. The brushless motor according to any one of claims 1 to 9, wherein a plurality of stator cores (1) are stacked axially, and each of the plurality of stator cores (1) comprises at least one phase wire (3), and a plurality of tooth groups (11) staggered in the circumferential direction of the stator cores (1).
  11. The brushless motor according to any one of claims 1 to 9, wherein in a whole target rotational speed range of the rotor (2), the driving signals applied to all phase wires (3) have the same strength.
  12. The brushless motor according to any one of claims 1 to 9, wherein: in a case where a target torque of the rotor (2) is higher than a first preset torque, the driving signals applied to the phase wires (3) have the same strength; and in a case where the target torque of the rotor (2) is not higher than the first preset torque, the driving signals applied to some phase wires (3) have a preset strength, and the driving signals applied to the other phase wires (3) have a strength lower than the preset strength or the other phase wires are not driven.
  13. The brushless motor according to any one of claims 1 to 9, wherein the brushless motor has a first working mode, in which each phase wire (3) is energized all the time with the driving signals to adjacent phase wires (3) having a phase difference.
  14. The brushless motor according to any one of claims 1 to 9, wherein the brushless motor has a second working mode, in which each phase wire (3) is energized intermittently, with the driving signals to adjacent phase wires (3) having a phase difference.
  15. The brushless motor according to any one of claims 1 to 9, wherein the magnetic ring (21) is sleeved over the stator core (1).
  16. The brushless motor according to any one of claims 1 to 9, wherein the stator core (1) is annular and sleeved over the magnetic ring (21).
  17. The brushless motor according to any one of claims 1 to 9, wherein the stator core (1) and the magnetic ring (21) are stacked along an axial direction, and the magnetic ring (21) at least partially covers the coils (31) along a radial direction of the stator core (1).
  18. The brushless motor of claim 17, wherein: the magnetic ring (21) comprises a plurality of magnetic rings (21) arranged on both sides of the stator core (1) along an axial direction; and/or the stator core (1) comprises a plurality of stator cores arranged on both sides of the magnetic ring (21) along the axial direction.
  19. An apparatus comprising the brushless motor according to any one of claims 1 to 18.
  20. A manufacturing method for a brushless motor according to any one of claims 1 to 18, comprising: a wire supply step: providing a wire (3); a winding step: winding the wire (3) around the plurality of tooth groups (11) in a phase sequence until a coil (31) is formed on each of the plurality of tooth groups (11); for all the coils (31) on the same phase wire, the number of tooth groups (11) spaced between the coils (31) on two adjacent tooth groups (11) being X -1, and the winding directions of the coils (31) on two adjacent tooth groups (11) along the circumferential direction of the tooth groups (11) being opposite; and a wire cutting step: cutting the wire (3) at a joint of adjacent phase sequences, so that the total number of phases of the wire (3) is X, and each phase wire (3) has a first end and a second end independent of each other.

Description

TECHNICAL FIELD The present disclosure relates to a brushless motor, a method for manufacturing the same, and an apparatus. BACKGROUND Brushless direct current (DC) motors have the advantages of conventional DC motors while eliminating carbon brushes and slip rings, and enabling low-speed, high-power operation. They are not only compact and lightweight, but also offer excellent stability and high efficiency, making them widely used across various fields. At present, although different types of brushless motors can basically meet the use requirements, it is still difficult to achieve good comprehensive performance, mainly because it is difficult to take into account all the various performance indicators, such as the torque and efficiency, and only the most important performance indicators can be preferentially guaranteed according to the use demands when selecting the motor type. Therefore, the comprehensive performance of brushless motors needs to be further improved to better meet the requirements of automatic driving. SUMMARY Some embodiments of the present disclosure provide a brushless motor, a method for manufacturing the same, and an apparatus, which can improve the comprehensive performance of the brushless motor. According to a first aspect of the present disclosure, there is provided a brushless motor including: at least one stator core including a plurality of tooth groups arranged at intervals along its circumferential direction, the total number of the tooth groups being Z;a rotor rotatable relative to the stator core and including a magnetic ring with P poles, P being an even number; andat least two phase wires wound around the tooth groups to form their respective coils, the total number of phases of the phase wires being X, and each phase wire having an independent first end and second end; for the same phase wire, the number of tooth groups spaced between the coils on two adjacent tooth groups being X-1, and the winding directions of the coils on the two adjacent tooth groups along the circumferential direction of the tooth groups being opposite;where Z=P*X. In some embodiments, the tooth group includes a single tooth, and the wire is wound around the tooth to form a coil on the tooth; and/or the tooth group includes at least two teeth, the at least two teeth are arranged at intervals along the circumferential direction of the stator core, and the wire is wound around the at least two teeth to form a coil on the at least two teeth. In some embodiments, each phase wire is configured to be applied with an independent driving signal. In some embodiments, in a radial direction of the stator core, the winding direction of each coil formed by the at least two phase wires is the same. In some embodiments, an initial winding position of each coil formed by the at least two phase wires is located on a side away from the rotor. In some embodiments, in the radial direction of the stator core, both the first end and the second end of the at least two phase wires are led out from the same side of the tooth group. In some embodiments, in the circumferential direction of the stator core, all the first ends and the second ends are led out from a plurality of adjacent tooth groups. In some embodiments, for the at least two phase wires, winding directions of the coils with the same sequence number from the first end along the circumferential direction of the tooth groups are the same; or for at least one group of adjacent two phase wires, the winding directions of the coils with the same sequence number along the circumferential direction of the tooth groups from the first end are oppsite. In some embodiments, the at least two phase wires are sequentially wound in a sequence from the first phase to a X-th phase along the circumferential direction of the stator core. The wires applied with driving signals include an i-th phase wire and a k-th phase wire, and the phase difference between the driving signals to the i-th phase wire and the k-th phase wire is θik=P2∑ik−1βX, where 1≤i<k≤X. In the same stator core, a gap is present between the tooth group of the x-th phase wire and adjacent tooth groups on both sides at their closest positions, and the gap has a central position in the circumferential direction of the stator core. Among all gaps formed by the Z tooth groups, a central angle corresponding to an arc between a central position of the x-th phase wire and an adjacent central position in the circumferential direction of the stator core is βX, and a sector corresponding to βX includes at least part of the tooth group of the x-th phase wire. In some embodiments, a plurality of stator cores are stacked in an axial direction, and each stator core contains at least one phase wire. In the circumferential direction of the stator cores, the respective tooth groups of the plurality of stator cores are staggered. In some embodiments, in the whole target rotational speed range of the rotor, the driving signals appl