Brushless DC motor and its rotor magnet

Abstract: The invention relates to a brushless DC motor comprising: a stator (2) having magnetic poles (3a-3d) with coils (4a-4c) and inter-poles (5ab,5bc,5cd,5da); a rotor (10) made of a cylindrical magnet (11) radially magnetized; and a rotor position sensor (6). The present invention has for its object such a brushless DC motor and a rotor magnet to be used therein, wherein said rotor magnet is entirely magnetized with no non-magnetized areas required, facilitating the magnetization, and space distribution of magnetic flux density is less uneven. To achieve this object, said rotor rotates around said stator, and said rotor magnet having magnetic grooves (12a,12b) on its inner surface facing the stator is entirely magnetized. Preferably said rotor position sensor (6) is made of a single magnetizing converter arranged in a position facing the inner surface of the rotor magnet.

Description: Technical field of the invention A brushless DC motor comprising: a stator having stator magnet poles and inter-poles; a rotor consisting of a rotor magnet lined on the inner wall of the rotor yoke and being composed of magnetic zones same in shape and in number of said stator magnet poles, each zone being magnetized radially and differently from the two adjacent zones, so that each magnetic zone is magnetized identically as the diametrically opposite magnetic zone. Prior Art A motor of this kind is disclosed in US patent no. 3,299,335. In this motor the magnetic pattern formed on the rotor magnet divides the rotor circumference into 3P / 2 equal sectors, where P is the number of poles, in the order N pole, S pole and non-magnetized area. This magnetised pattern keeps the electromagnetic force from vanishing at a certain rotor position and so stabilises starting of the motor. The problems of the prior art The prior art motor enjoys stable driving torque and small detent torque, but it requires mon-magnetised areas at the rotor magnet. This, however, makes it difficult to mass-produce such motors of uniform characteristics. Also differences in the used magnetising devices (magnetisation power supply, magnetisation voltage, electrostatic capacity of power supply, etc.) or changes of surrounding temperature cause an uneven space distribution of magnetic flux density. Being largely dependent on the magnetic pattern of the rotor magnet, the motor characteristics vary acutely when space distribution of magnetic flux density is uneven. Furthermore, if a magnetic field sensor is used for rotor position sensing, a rotor position sensing magnet is needed in addition to the torque-generating rotor main magnet. This makes the rotor construction even more complicated. The same is true with certain motors according to the FR-A-2 386 928. This document also shows motors with grooved rotor magnets, which have only one pair of poles. These motors are more simple and therefore more easy to be fabricated, but because of only two poles, there are only two pulses for each revolution, and therefore the power is reduced. Four-poled rotor magnets are also disclosed, in which the magnet consists of a single cylindrical anisotropic magnet (Fig. 23A), or of zones of different magnetic materials (Fig. 25), or in which a pair of grooves is provided, each extending over half the circumference of the rotor (Fig. 28). Object and solution of the invention The present invention has for its object to eliminate the problems of the prior art as thus far described and relates to a brushles DC motor and a rotor magnet to be used therein, wherein said rotor magnet is entirely magnetised with no non-magnetised areas required, facilitating the magnetisation, and space distribution of magnetic flux density is less uneven, without rotor position sensing magnet and with great power. The invention solves the problems by the following features: The rotor magnet has no non-magnetized areas; a pair of axially directed grooves is provided, one of which lies directly opposite to the other, one half of each groove being formed in a respective one magnetic zone, the other half being formed in the adjacent magnetic zone; and a single magnetic field sensor is arranged in a position facing the grooved surface of the rotor magnet to cooperate therewith to provide a rotor position signal. "Grooves" refers also to an instance where non-magnetised reinforcements are filled in such grooves and even to an instance where plastic magnets are filled in the grooves cut in a high-performance magnet such as a rare-earth magnet. Preferred embodiments Brief explanation of the Drawings Fig. 1 shows in cross section a motor according to this invention. Fig. 2 shows the rotor magnet used in Fig. 1. Fig. 3 is a graphic of surface distribution of magnetic flux density of the magnet. Fig. 4 is a sectionial view of a fan motor to which this invention is applied as one of its applications. Fig. 5 A-E show sectional shapes of the groove cut in the respective rotor magnet. Fig. 6 and 7 show diffent shapes in a cross sectional view of the rotor magnet. Fig. 8 and 9 show a different structure in a sectional view of the rotor. Detailed description Figure 1 is a principle view of the brushless DC motor relating to this invention and an example of a 4 pole outer-rotor-type motor. The stator consists of a stator yoke 2, four stator magnet poles 3a, 3b, 3c, 3d, positioned to the stator yoke 2 in succession at an angle of 90°; around each stator pole a coil 4a, 4b, 4c and 4d is wound, and four inter-poles 5ab, 5bc, 5cd and 5da are positioned just between the magnet poles. A magnetic converter 6 detects the position of the rotor; this converter 6 is a hall element or the like, installed on top of inter-pole 5bc. The rotor consists of a cylindrical rotor yoke 10 and a rotor magnet 11 at the inside of rotor yoke 10 with a rotor axis (not illustrated) for free rotation. The details of the rotor magnet 11 are shown in Figure 2, and the magnetic flux density at its surface in Figure 3. Rotor magnet 11 is radially magnetised with four poles and has two grooves 12a, 12b. One half of each groove is formed in the one magnet piece, the other half is formed in the respective adjacent magnet piece. The central angle of each groove is 2 ϑ, counting from the neutral point or magnet switching point 1 ϑ at the one magnet piece and 1 ϑ at the adjacent magnet piece. The surface magnetic flux density of the rotor magnet 11 is shown in Figure 3. At the grooves 12a, 12b (within angle 2 ϑ) the magnetic flux density at the surface, with which the magnetic poles of the stator are intersected, is low and changes from South to North. The order of the grooves and the magnetic poles is as follows: N-pole (90° - ϑ) → S-pole (90° - ϑ) → Groove S-pole (ϑ) → Groove N-pole (ϑ) → N-pole (90° - ϑ) → S-pole (90° - ϑ) → Groove S-pole (ϑ) → Groove N-pole (ϑ). One characteristic of this Invention lies in the following: the magnetic grooves are formed so as to give magnetic changes in a circumferential direction, and the rotor magnet is so constructed that is can be magnetised without any non-magnetised area, and so a rotor position detecting magnet is not necessary. The operation principle of such motor is the same as that of the aforementioned conventional technology. With the position relationship between rotor magnet 11 and magnetising converter 6 fixed as shown in Figure 1, if coils 4b and 4d are energised, and stator magnetic poles 3b and 3d are excited to N poles respectively, the N poles of rotor magnet 11 and the N poles of stator magnetic poles 3b and 3d repel each other magnetically and the rotor rotates anti-clockwise (in the direction of the arrow). After 90° rotation, coil 4b and 4d are de-energised, and coils 4a and 4c are energised. This causes stator magnetic poles 3a, 3c, to be excited to N poles respectively. As the result, the motor continues to rotate anti-clockwise because the N pole of rotor magnet 11 and the N poles of stator magnetic poles 3a and 3c repel each other magnetically. Inter-poles 5ab, 5bc, 5dc and 5da function as a generator of torque (no dead point) at any positions of the rotor. Each time the rotor rotates through 90°, magnetic field sensor 6 detects the changes of the magnetic poles and energises the pair of coils 4a and 4c, and the pair of coils 4b and 4d alternatively. This causes the rotor to rotate continuously in one direction. In connection with this invention, an experiment was made with rotor magnets 11 shown in Figure 2 and for comparison with a conventional-type rotor magnet, to find the effects of groove angles ϑ on the characteristics of the motor. With four different angles, 15°, 20°, 30° and 40° of the groove 12a, 12b, when a motor axis torque of 10g-cm was applied, the motor rotation numbers, the motor current and the motor efficiency were measured. The results are shown in the following table: The Table shows that compared with the conventional technology, this Invention produces a low current value and a rise in efficiency of 1 to 6 %. With a 4-pole magnetised rotor magnet, it became clear that the motor is most efficient in the vicinity of ϑ = 30°. The experiment shown in the Table was made based on the relationship of t2 = 4t1, in which the gap between the rotor magnet and the stator is t1, and the gap between the groove and the stator is t2. This is determined by the magnetic flux density distribution and the experiment results. Therefore, it is desirable that the shape of the groove formed in the rotor magnet should be designed to satisfy the following two formulas : 0,3 x 360 / P < 2 ϑ < 360 / P D ≧ G Where: 2 ϑ : Groove width (degrees) in the stator opposing surface as viewed from a central angle P: Number of magnetised poles D: Center depth of the groove G: Minimum gap between the stator and the rotor magnet The brushless motor related to this invention is applicable for many purposes. Good starting and high efficiency are the characteristics of the motor, which is suitable for products such as fan-motors. Figure 4 shows a fan with a motor according to the invention. Same parts have the same reference numbers as in Figure 1. Impeller 40, molded in one piece with synthetic resin, has in the inner side the Rotor Yoke 10 which is heat-clinched and fastened. Rotor shaft 18 is free to rotate in bearings 44 and 45 fitted into the housing 42, and is held in position with a retaining ring 48 after a spring 46 is adjusted to a given preload. The stator, with coil 4a ... 4d wound on the stator yoke 2, laminated and then insulated, is fixed to the bearing holder located in the center of the housing 42. Circuit board 50 is fastened with screw 51 to the inner side of housing 42. A logic circuit for coil excitation conversion, switching elements and magnetic field sensor 6 for rotor position sensor etc. are mounted on the circuit board 50, to which the terminal of each coil 4a ... 4d is also connected. The required power is supplied from the outside source with wire 52. The groove in the rotor magnet is not limited to a single rectangle shape. There may be other different shapes such as examples A-E in Figure 5. ex A shows a V-shape groove. ex B is a semicircle. ex C is a groove with R-shape on both sides of its bottom. ex D is a groove of which the bottom is curved out on both edges. ex E is a groove of which the bottom is shaped to form a swelled curve toward the face of the stator. Other examples of the rotor magnet are shown Figures 6 and 7. To improve the characteristics, the rotor magnet may be made of a high performance magnet such as a sintered or a rare-earth magnet. If they would be used for the whole of the rotor magnet, however, it would be costly, far from cost-effective in many cases. Therefore, Fig. 6 shows that high quality magnets 52 such as sintered or rare-earth magnet are used in the desired location of, and as part of, the rotor magnet and cheaper and easy-to-mold plastic magnet 51 are used in the desired shape for the remaining part. That is the way the rotor magnet comes out well in cost performance. Fig. 7 is a structure with appropriate reinforcement material 53 filling up the grooved part of the rotor magnet 54. For instance, non-magnetic plastics serve the purpose of reinforcement 53. Moreover, plastic magnets are adaptable as reinforcement 53 for the rotor magnet 54, in which high performance magnets such as sintered or rare-earth magnets are used. Fig. 8 and Fig. 9 show a practical structure of the rotor. If the impeller must be joined with the rotor like a fan-motor for instance, it should be designed to make a combination of rotor magnet 56, shaft 55 and reinforcement 57 (impeller for fanmotor) in a complete form and unit, as in Fig. 8. Fig. 9 is another combining form in which rotor magnet 56 and shaft 55 are joined by reinforcement 58, that incorporates gears on the circumference. Such instances of structure are not all that this invention covers. The type explained above is an outer-rotor type motor. In like manner, an inner-rotor type can be made up in a combining form with high efficiency gained as well without counting on a driving system or a number of magnetic poles. Of course it is possible to make changes of the magnet, the reinforcement material and the components structured by the reinforcement. This rotor is applicable to a photoelectro-type rotor position sensor system in addition to a magnetic field sensor aided rotor position sensor system.

Claims: A brushless DC motor comprising: a stator having stator magnet poles (3a, 3b, 3c, 3d) and inter-poles (5ab, 5bc, 5cd, 5da); a rotor consisting of a cylindrical rotor magnet (11) lined on the inner wall of a rotor yoke (10) and being composed of magnetic zones of the same shape and equal in number to the said stator magnetic poles, each zone being magnetized radially and differently from the two adjacent zones, so that each magnetic zone is magnetized identically to the diametrically opposite magnetic zone; characterized in that: the rotor magnet (11) has no non-magnetized areas; a pair of axially directed grooves (12a, 12b) is provided, one of which lies directly opposite to the other, one half of each groove being formed in a respective one magnetic zone, the other half being formed at the adjacent magnetic zone; and a single magnetic field sensor (6) is arranged in a position facing the grooved surface of the rotor magnet (11) to cooperate therewith to provide a rotor position signal. Motor according to claim 1, characterized in that the shape of the grooves (12a, 12b) is represented by the following two formulas: 0.3 x 360° / P < 2 ϑ < 360° / P D ≧ G, wherein P is the number of magnetized poles, 2 ϑ is the angle subtended by each groove at the centre of the rotor, D is the depth of the grooves at their centre, G is the smallest gap between the stator and the rotor magnet. Motor according to claim 1, characterized in that magnetic materials of different properties are combined for forming the rotor magnet (11). Motor according to claim 1, characterized in that reinforcement material (53) is filled in the grooves (12a, 12b).

Inventors: FUJITANI SAKAE, SUZUKI YUZURU, TAKAHASHI HITOSHI, FUJITANI, SAKAE, SUZUKI, YUZURU, TAKAHASHI, HITOSHI
Applicants: MINEBEA KK, MINEBEA CO.,LTD.
Application year: 1989
Main classification: H02K29
IPC codes: H02K29, H02K1