The present invention relates to electric motors. More specifically, the invention relates electronically commutated brushless motors.
Brushless DC motors are widely used in hobby applications such as model aviation. The advent of lithium secondary batteries and low “on” resistance power integrated circuits have permitted rapid advances in model aviation. The high power to weight ratios now available with electrically commutated motors powered by lithium batteries have permitted sustained flights of model helicopters and high speed ducted fan powered model jets. Traditional brushless motor designs for model aviation are derived from the CD/DVD-ROM drive industries. Despite recent advances, there is a continuing need for better brushless motors. More power handling ability and lighter weight than can be achieved by the older motor designs are advantageous in the application of modern model aircraft.
The motor of the present invention achieves very high performance and exhibits a very wide efficient operating range. The permanent magnet structures are carried on a rotor that overhangs and surrounds the inner stator. The rotor spins outside the stator structures in a configuration commonly called “outrunner”.
The rotor is an insert injection molded piece with features to locate permanent magnets. The stator includes the armature structure and is very compact. The armature laminations form radial spokes, about which relatively thick (low gauge) wire is wound in a single layer. In contrast to conventional practice in which the armature is filled with as much conducting material as possible, radial slots between the spokes allow air to circulate across the wire. The inner hub from which the spokes radiate has a small diameter. Because of the combination of these two aspects, the ratio of open space to solid material in the winding core is low compared to conventional practice.
After the wire is wound around the spokes, a wedge is used to hold the wire tightly against the spokes while the wire is varnished into place. Because of the substantial contact consequently achieved once the varnish cures between the wire and the armature laminations, the armature laminations serve as a sink for heat generated in the wire when the motor is operational.
Several other features also contribute to improving heat transfer away from the wire coils, thereby improving performance. The end bells enclosing the winding core at both ends are open. The rotor end bell has deep blades, effectively pushing the air like a fan as the shaft rotates. The mounting end bell includes skeletal struts that reduce resistance to air flow, both axially and radially. The openings through the winding core and the end bells combine to facilitate axial air flow to cool the conducting material in the single layer of wire.
The rotating components are supported by a very low profile collection of bearings. The overall design structure and construction techniques permit sustained dissipation of heat and remarkable efficiency at all power settings in a lightweight assembly.
The figures and associated text illustrate exemplary embodiments, which are not intended to be comprehensive of the scope of the invention. A person of ordinary skill in the art will recognize many embodiments of the inventive concept that are not explicitly detailed here.
The motor 100 includes a rotor assembly 105 and a stator assembly 150. The rotor assembly 105 is made up of a rotor cylinder 110 and the power delivery shaft 115, insert-molded into a rotor end bell 120 (also known as a rotor end “cap”). The rotor end bell 120 includes a plurality of blades 127, typified by blade 127a, for structural support. A roll pin 122 through the shaft 115 is encapsulated by the rotor end bell 120, ensuring the coupling of the rotor end bell 120 to the shaft 115 as the shaft 115 rotates. While the rotor end bell 120 is being molded, the mold holds the rotor cylinder 110 and the power delivery shaft 115 in proper axial and radial relationship.
The rotor end bell 120 is fabricated from structural thermoplastic. Any of a number of thermoplastics may be used, but RYTON R-4-200BL, a composite of resin and fiberglass, is one thermoplastic found to have the advantages of high strength and the ability to withstand high temperatures. All the thermoplastic parts in the motor may be fabricated from RYTON R-4-200BL or similar material.
The stator assembly 150 includes the armature assembly 155, which is supported, at least in part, by a bushing support 160. The bushing support 160 is in turn supported by the mounting end bell 165 (also known as a “stator end bell/cap”), which is also a molded structural thermoplastic part. These elements are stationary when the motor is operating. The framework of the mounting end bell 165 includes a plurality of struts 167, typified by 167a, describing openings 168. The stator assembly 150 includes a mounting flange 175, which has mounting holes 170, typified by mounting hole 170a, to mount the motor 100 for use. In the embodiment shown, bearings 180, 185 and 190 facilitate smooth rotation of the shaft 115. Bearing 185 is enclosed by a bushing 195 within the bushing support 160. Other than the bearings and the bushing 195, the remainder of the shaft enclosure 196 may be fabricated from structural thermoplastic.
The armature assembly 155 is formed from a stack 330 of laminations 200, each lamination 200 oriented perpendicular to the Z-axis in an assembled motor 100. A representative lamination 200 is shown in
The lamination 200 is stamped from thin, flat, metal, such as steel, that has a high magnetic permeability. The lamination 200 may have small indentations (not shown) in its surface, for alignment with adjacent laminations in the stack 330. At the center of the lamination 200 is a circular shaft hole 205, through which the shaft 115 of the rotor assembly 105 passes. (It should be noted that not all laminations 200 have the same shaft hole 205 size. The radius of the shaft hole 205 may be enlarged in some laminations 200 relative to others, to serve as a counterbore 320 to hold bushing 195 or bearing 180. In some laminations 200, the shaft hole 205 in the lamination 200 may be modified by a key 325, a groove used for alignment. Such a counterbore 320 and a key 325 are shown in
Each spoke 225 terminates in a spoke cap 230, typified by spoke cap 230a. The outermost edges of the spoke caps 230 lie on a circle 235, about which the rotor cylinder 110 rotates (see
The wire 250 that wraps each spoke 225 in the winding core 340 is conducting wire 250, typically copper or copper-based. Because wire heat is proportional to wire resistance, which is, in turn, inversely proportional to area, according to conventional reasoning, the wire should be wrapped with a plurality of layers of thin gauge copper wire. Accordingly, the available core volume in an armature 155 is typically filled with the maximum practical amount of conductor volume, so that no valuable armature core is wasted as air space.
The inventor has found that the conventional approach is prone to thermal runaway. At high power density, as power continues to increase, temperature increases, which causes power to increase, and so forth. Eventually, the winding core will burn up.
Applicant has realized that the conventional approach of using multiple layers of copper wire prevents the inner layers from exposure to cooling air. In contrast, the spokes 225 in the winding core 340 shown in
The winding may be performed by a machine that translates as the wire, under tension, is looped around a spoke, so that adjacent wire loops are positioned radially closely adjacent to each other. After winding, a winding wedge 400 is inserted between adjacent spokes to keep the wire 250 flush against the spokes 225. An example of a wedge 400 is shown in
The resulting ratio of wire 250 area to slot 245 area in cross-section through the winding core 340 is optimized for lowest resistance-induced energy loss to heat, at peak power output. Returning to
A person of ordinary skill in the art will recognize that alternative geometries are possible that can also achieve such a high ratio of space to solid material area in the axial direction through the winding core 340. For example, the spokes 225 may be different from those of the winding core 340 shown in
In addition to increasing the space for air flow through the armature 155, the above-described winding/wedging/varnishing process achieves close contact between the wire 250 and the laminations 200. Thus, the entire winding core 340 becomes a sink for heat produced when electricity flows through the wire. This effect of increasing the heat capacity of the winding core 340 also contributes to preventing thermal runaway.
A small counterbore 320 in the armature assembly 155 seats bushing 195 and bearing 185 (see
Just as the winding core 340 cross-section can vary in geometry without departing from the inventive concept, so can the detailed geometry of the mounting end bell 165. Essentially, the mounting end bell 165 should be rigid and substantially permeable to air flowing at least axially. The axial ratio of space to solid material in the mounting end bell 165 should be at least 25%, and preferably should be greater than 30%. Like the armature 155, the mounting end bell 165 has a central hub 520, bounded by a circle. In a projection of the type shown in the figure, the projected (i.e., axial) ratio of space to solid material in the mounting end bell 165 outside the central hub 520 should be at least 30% and preferably should be greater than 40%. Because of their curving skeletal shape, the struts 167 of the mounting end bell 165 shown in
The mounting end bell 165 might have struts 167 having shapes different from those shown in
In the embodiment shown, when viewed from the side as in
Again, other geometries of the blades 127 are possible within the scope of the invention. The blades 127 may differ in shape and/or number, or have some other geometry entirely. For example, while each blade 127 shown in
The motor 100 may be mounted in or on a superstructure, such as a model airplane or helicopter, such that air will impinge upon the motor as a result of the motion of the superstructure. In such situations, the permeability of the motor 100 to relative air velocity parallel to the axis not only will cool the components of the motor 100, but also may reduce resistance of the superstructure to forward motion. The motor 100 might drive a ducted fan or a propeller.
In some embodiments, a motor 100 may be constructed, using structures and methods described herein, that weighs at least 120 grams and can produce an average of at least 1600 watts of power over an interval of at least 150 seconds, with the temperature of the wire 250 not exceeding 140 Celsius.
Of course, many variations of the above method are possible within the scope of the invention. For example, the respective structures of the mounting end bell and the rotor end bell can vary considerably while still allowing substantial axial air flow consistent with the inventive concept. The present invention is, therefore, not limited to all the above details, as modifications and variations may be made without departing from the intent or scope of the invention. Consequently, the invention should be limited only by the following claims and equivalent constructions.
This application claims the benefit of U.S. Provisional Application No. 61/130,912, filed Jun. 4, 2008, having inventor Leslie Hoffman and entitled “Brushless Motor Apparatus,” and hereby incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61130912 | Jun 2008 | US |