Brushless DC motor and method for driving the same

Abstract: In a radial gap type brushless DC motor having a motor structure for generating a starting torque and lowering rotational speed fluctuation by forming either one of a pair of upper and lower (right and left) claw poles to have a smaller interval in the circumferential direction with respect to the other claw pole, shifting the position of the upper or lower claw poles toward the rotating direction of the rotor from the middle position of the other claw pole and claw pole, and setting a ratio (a/p) of the claw pole width a and the pole pitch p, a ratio (b/a) of the claw pole width a and the claw pole width b, and a ratio (c/d) of the claw pole pitch c and the claw pole pitch d to fall in a prescribed range, a method for driving a motor forms the generated torque cycle of a cogging torque generated between a permanent magnet rotor (2) and a stator into large and small torque waves, and switches the current of a coil (12) at a high peak of absolute quantity or in the vicinity thereof among a plurality of positive peaks of the cogging torque. Further, a method for driving a motor wherein the coil current is switched at a position where the excited torque generated by the coil current becomes zero or in its vicinity. And, a method for driving a motor wherein the coil current is switched in a vicinity of a positive peak of the cogging torque and giving a no-current passing period when switching the coil current.

Description: This invention relates to brushless DC motors and is applicable to a brushless DC motor structure which excels in self-starting reliability and has reduced rotational speed fluctuation. A conventional radial gap type brushless DC motor has a rotor 51 consisting of a cup shaped back yoke 52, an annular permanent magnet 53 adhered to the inner wall of the back yoke, and a shaft 55 inserted in a bush 54 at the center of the back yoke 52, as shown in Fig. 34. In the drawing, the reference numeral 56 represents a turn table. A stator 57 consists of first and second stator yokes 58, 59 made of soft magnetic metal plate and a coil 60 disposed between the both stator yokes 58, 59 as shown in Fig. 35. These stator yokes 58, 59 have claw poles 58a, 59a which are pole pieces radially extending outward from the center and bent at right angles, and integrally formed rings 61,62 at the center along the direction in which the claw poles 58a,59a are bent. In the drawing, the motor has four poles. The first stator yoke 58 and the second stator yoke 59 of the stator 57 are assembled with the coil 60 therebetween. A ring 61 and another ring 62 are joined to be magnetically connected to form a magnetic circuit. And, keeping a prescribed gap from the circumference of the permanent magnet 53 of the rotor 51, the claw poles 58a and the claw poles 59a of the first stator yoke 58 and the second stator yoke 59 are alternately disposed in the circumferential direction. Further, a sleeve 63 is mounted within the ring 61 of the stator 57, and the shaft 55 of the rotor 51 is supported within the sleeve 63 via a bearing 64. At the bottom of the sleeve 63, a base plate 65 is fitted to support the stator 57, and a circuit substrate 66 is fixed to the base plate 65. In the drawing, the reference numeral 67 indicates a Hall element which is a sensor for detecting the magnetic pole of the rotor, and G indicates a gap. In a conventional brushless DC motor, the width a of one claw pole Xx is generally the same as the claw pole width b of the other claw pole Yy as shown in Fig. 36 and Fig. 37 (a) and the claw pole pitch c from the one claw pole Xx to the other claw pole Yy is set to be equal to the claw pole pitch d from the other claw pole Yy to the one claw pole Xx. In other words, claw poles having equal claw pole width are combined at equal intervals. When a torque curve in this case is drawn (vertical axis: torque T, horizontal axis: machine angle ). Fig. 37 (b) shows that when a cogging torque shown by a solid line (torque due to attraction by the magnet and stator yoke) reaches point B (unstable point: mark Δ ) at 180 degrees in electrical angle (for one magnetic pole in machine angle) from point 0 (unstable point: mark Δ ) via point A (stable point: mark o) in the rotation for one magnetic pole of the rotor, a negative torque works from point A and forward to generate a returning force to the rotor, and when the rotor is rotated in the opposite direction, a positive torque works to generate a force to point A. Suppose the position of the Hall element is point C, polarity is switched at this point C, and the generated torque shown by a dotted line (torque which is generated when electric current flows and the sum of the excited torque and a cogging torque generated by the coil current) drops at point C as illustrated, generates a negative torque in the illustrated shaded area, and moves forward through point B. When the negative torque is generated, a dead point (point where self-starting is impossible) is always generated. This dead point is B in the drawing. The rotor stops at point A which is a stable point when the motor is under no load, but since it does not always stop at point A when an external load is on the motor, the motor cannot rotate even when electric current flows if the rotor stops at point B. Generally, the motor is used as so-called actuator and under some load as described above. And, since the rotor does not always stop at so-called stable point, a dead point is generated, and when the rotor is positioned at the dead point, this results in the drawback that the motor cannot be used in most cases. In a technique capable of improving self-starting reliability the stator yoke is generally disposed to generate a magnetic unbalance on the circumference where an air gap is formed, to cause the static stable position of the permanent magnet rotor to deviate from a position of excited torque zero. For example, Japanese Patent Application Laid-open Print No. 23754/1989 uses the stator yoke having claw poles with an equal width, and disposes the claw poles at unequal intervals. According to this art, self- starting reliability is improved, but since the negative torque cannot be eliminated at the point where polarity is switched, the dead point still exists. As techniques to eliminate the negative torque, Japanese Patent Application Laid-open Print Nos. 229637/1985, 150643/1986 and 4454/1986 are known. They provide special shaped claw poles to prevent the generation of a negative torque under the excited condition. But, they have the drawbacks that the claw poles have a complicated shape and cannot be fabricated easily, resulting in difficulty in obtaining high fabrication accuracy, and magnetic control and rotation control are difficult. A motor described in Japanese Patent Application Laid-open Print No. 144788/1988 is know, which improves self-starting reliability by using the driving circuit of the motor. When a Hall element is generally used to switch the polarity of the applied voltage to the motor coil, it is controlled to give a no-current passing period when switching, to remedy the degradation of self-starting reliability due to excessively late or early switching timing of the polarity of the applied voltage to the coil. Although such control can avoid the generation of a negative torque to give the no-current passing period when switching, when the voltage value of the detected signal of the Hall element varies, this no-current passing period changes accordingly, resulting in the drawback that a large negative torque is generated. And, this conventional radial gap type brushless DC motor has been generally developed to remedy the impossibility of self-starting and a specific measure is not taken to reduce the rotational speed fluctuation. In this connection, the motor described in the aforementioned Japanese Patent Application Laid-open Print No. 150643/1986 reduces the rotational speed fluctuation by disposing a third claw pole between first and second claw poles, but the shape of the claw poles is complex and their fabrication is difficult as described above, so that it has the drawbacks that high fabrication accuracy is hardly obtainable, and magnetic control and rotation control are difficult. Thus, it is not practical. In JP 61214760 is described a brushless motor rotor so designed as to reduce the size and the weight of the motor by displacing a pair of stator poles disposed at both ends of a coil of a rotor side at different widths, thereby self-starting to rotate. The motor is composed of cylindrical and disc-shaped stator cores and a coil. The core is formed with the first stator pole suspended axially inward from the edge, integrally formed in the width of 150∼180°, and magnetic detecting means is provided near a hole. The second stator pole is stood similarly at the core, and provided at the position displaced at 200∼225° of rotating direction in the half width of the first stator pole. The output shaft 21 of a permanent magnet rotor is supported through a bearing at a mount. Thus, since the stable position at deenergizing time is displaced in the rotating direction from the stable position of the rotor 20 at energizing time, a self-starting property is obtained, such that the axial length is shortened. Similarly, JP 61214759 discloses a brushless motor rotor bring about a reduction in size and weight by displacing a pair of stator poles disposed at both ends of a coil of a rotor side at different widths, and opposing a permanent magnet rotor thereto, thereby initiating rotation. The motor is composed of disc-shaped stator cores and a coil, and cylinders are formed at the centers of the cores. The first stator poles are suspended from the symmetrical position of the peripheral edge of the core in the width of 350∼180° of electric angle, the second stator poles at the symmetrical positions of the peripheral edge of the core at the positions displaced at approx. 200∼225° of electric angle in the rotating direction by the half width of the width of the pole. Magnetic detecting means is disposed at the side of the first stator pole at a motor mounting stand, and the output shaft of a permanent magnet rotor is supported by a bearing. Thus, the stator position at deenergizing time is displaced to the rotating direction from the stable position of the rotor at energizing time to obtain self-starting behaviour. In view of the above circumstances, this invention aims to provide a motor structure and a method for controlling the rotation of a motor, whose self-starting reliability can be improved and whose rotational speed fluctuations can be reduced by a relatively simple structure. The applicant has proposed a motor to accomplish the above object while keeping identical the shapes of first and second stator yokes made of soft magnetic metallic plate (Japanese Patent Application No. 297411/1991). As shown in Fig. 38, claw pole 58a and claw pole 59a of the first stator yoke 58 and a second stator yoke 59 are alternately disposed, the claw poles 58a, 59a are formed to have the same claw pole width, the position of a static stable point due to the cogging torque is structured adjacent to the maximum torque point of an excited torque generated by passing current through a coil, and a sensor for detecting the poles of a permanent magnet is offset from the middle of an opposing claw pole, so that self-starting is possible. Specifically, the ratio of claw pole width m and pole pitch p of a permanent magnet 53 (m/p) is determined to be 75 to 85%. This invention proposes a motor structure where the claw pole shapes of first and second stator yokes are alternately different without being restricted by the ratio of claw pole width m and pole pitch p of a permanent magnet (m/p), or by slightly changing the structure from that of Japanese Patent Application No. 297411/1991, the claw pole shape is not so complex as the conventional one but systematic, and therefore high fabrication accuracy is obtainable, and magnetic control and rotation control are easy. According to the invention, there is provided a brushless DC motor as disclosed in claims 1 and 2. In this specification, "switching of coil current" means to change the direction of current flowing to the coil when the motor is rotated by a single-phase bipolar drive and to change coils to which current is supplied when rotated by two-phase, three-phase ... unipolar drive. For a better understanding of the invention and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which: Fig. 1 is a vertical sectional view showing a brushless DC motor; Fig. 2 is an exploded sectional view showing a brushless DC motor; Fig. 3 is a circuit diagram showing one example of the driving circuit of a brushless DC motor; Fig. 4 is a plan view showing a stator yoke and a magnet; Fig. 5 shows diagrams of a development elevation of claw poles and a torque curve; Fig. 6 shows diagrams of a development elevation of claw poles and a torque curve; Fig. 7 shows diagrams of a development elevation of claw poles and a torque curve; Fig. 8 shows diagrams of a development elevation of claw poles and a torque curve; Fig. 9 shows diagrams of a development elevation of claw poles and a torque curve; Fig. 10 shows diagrams of a development elevation of claw poles and a torque curve; Fig. 11 shows diagrams of a development elevation of claw poles and a torque curve; Fig. 12 shows diagrams of a development elevation of claw poles and a torque curve; Fig. 13 shows diagrams of a development elevation of claw poles and a torque curve; Fig. 14 shows diagrams of a development elevation of claw poles and a torque curve; Fig. 15 shows a graph of a torque curve; Fig. 16 shows a graph of a torque curve; Fig. 17 shows a graph of a torque curve; Fig. 18 shows a graph of a torque curve; Fig. 19 shows a two-phase unipolar type motor drive circuit using a no-current passing circuit; Fig. 20 is a block diagram of a no-current passing circuit; Fig. 21 is a drawing showing time charts of a no-current passing circuit; Fig. 22 is a table showing a self-activation characteristic when a/p=1.0; Fig. 23 is a table showing a self-activation characteristic when a/p=0.95; Fig. 24 is a table showing a self-activation characteristic when a/p=0.90; Fig. 25 is a table showing a self-activation characteristic when a/p=0.85; Fig. 26 is a table showing a self-activation characteristic when a/p=0.80; Fig. 27 is a table showing a self-activation characteristic when a/p=0.75; Fig. 28 is a table showing the generated states of non-uniformity of rotation when a/p=1.0; Fig. 29 is a table showing the generated states of non-uniformity of rotation when a/p=0.95; Fig. 30 is a table showing the generated states of non-uniformity of rotation when a/p=0.90; Fig. 31 is a table showing the generated states of non-uniformity of rotation when a/p=0.85; Fig. 32 is a table showing the generated states of non-uniformity of rotation when a/p=0.80; Fig. 33 is a table showing the generated states of non-uniformity of rotation when a/p=0.75; Fig. 34 is a vertical sectional view showing a conventional brushless DC motor; Fig. 35 is an exploded sectional view of a conventional brushless DC motor; Fig. 36 is a plan view showing a stator yoke and a magnet; Fig. 37 is a diagram showing a development elevation of claw poles and a torque curve; and Fig. 38 is a plan view showing a stator yoke and a magnet. In Fig. 1, a brushless DC motor 1 is constructed by combining a rotor 2 and a stator 10, and the rotor 2 consists of a cup-shaped back yoke 4, an annular permanent magnet 5 which is attached to the inner wall of the back yoke, and a shaft 3 which is press fitted to the center of the back yoke 4. The reference numeral 6 represents a turn table and 7 a chucking magnet. The stator 10 consists of a first stator yoke X shown at the upper part, a coil 12, and a bearing 18 which supports a stator yoke Y shown at the lower part, a sleeve 17 and the shaft 3 in Fig. 1 and Fig. 2 . Both the stator yokes X, Y are made of a soft magnetic metallic plate, which is stamped out into a certain shape whose portion extending radially is then bent at right angles to form claw poles Xx, Yy, ..., have the sleeve 17 to which the coil 12 is mounted therebetween, so that the claw poles Xx, Yy, ... are alternately disposed in the circumferential direction. The coil 12 consists of a resin bobbin 14 having a flange at each end and a winding 15 wound thereon. The above sleeve 17 is formed in a cylindrical shape and has a fitting part 17a formed in a projected shape at each end, which is fitted into fitting holes 11b, 16b formed at the center of the stator yokes X, Y. Besides, a pin 14a is projected from each flange of the bobbin 14, and holes 11c, 16c to be connected with the pins 14a are respectively formed in the stator yokes X, Y to determine the relative positions of the stator yokes X, Y in the circumferential direction when the stator yokes X, Y are assembled with the coil 12. And, after assembling the stator 10 from the first stator yoke X, the coil 12, the sleeve 17, and the second stator yoke Y, a fitting hole 19a of a circuit substrate 19 is fitted to a fitting projection 20a formed in a convex shape at the center of a base plate 20, and the bearing 18 is inserted from below the fitting projection 20a to assemble an entire motor. The bearing 18 has a flange 18a formed at the bottom, which is larger than the hole of the fitting projection 20a of the base plate 20, and is inserted upward from below into the sleeve 17, then is fixed within the sleeve 17 by caulking a top opening 18b which is enlarged with a jig. The reference numeral 21 represents a Hall element which is a sensor for detecting the position of a magnetic pole of the rotor. Furthermore, the circuit substrate 19 disposed on the base plate 20 is fixed by screwing through holes previously formed in the circuit substrate 19 and the base plate 20 so that the Hall element 21 disposed on the circuit substrate 19 is positioned at a prescribed position. As described afterward, since switching of the coil current by the sensor is conducted at a high peak of absolute quantity or in the vicinity thereof among a plurality of positive peaks of the cogging torque, the position of the Hall element 21 is determined to suit it. The position of the Hall element 21 on the circuit substrate 19 is basically the same as shown in Fig. 19 and is set at a position offset in the direction opposite from the rotating direction by 0 to 90 degrees in electric angle from the position of a stable point (right stable point of the torque curve shown in Figs. 5 to 14 to be described afterward) in a non-excited state. Fig. 3 is a circuit diagram of a single-phase bipolar drive showing one example of a driving circuit of the brushless DC motor where the Hall element 21 detects S and N poles of the permanent magnet to generate an output signal, transistors Q1, Q4 or Q2, Q3 are turned on or off accordingly, and the coil 12 is alternately supplied with current to excite the stator 10. A pair of claw poles R is set by two adjacent claw poles Xx, Yy among claw poles Xx, Yy, ... of the two stator yokes X, Y as shown in Fig. 4. In this example, the motor has a four-pole structure and, therefore, two pairs of claw poles R are provided. And, claw pole width a of the claw pole Xx and claw pole width b of the claw pole Yy are determined not to be equal, claw pole pitch c and claw pole pitch d of claw pole pitches c, d, c, d, ... connecting the midpoints of each claw poles Xx, Yy, ... are determined not to be equal, the claw pole width a of the claw pole Xx on the rotating direction of the permanent magnet rotor among the claw poles Xx, Yy of the each pair of claw poles is formed to be larger than the claw pole width b of the other claw pole Yy, and the claw pole pitch c from the claw pole Xx to the claw pole Yy is formed to be smaller than the claw pole pitch d from the claw pole Yy to the claw pole Xx. The structure of the motor will be described in comparison with a conventional one which combines claw poles having an equal claw pole width at an equal interval, so that the characteristics will be fully understood. The brushless DC motor according to any embodiment of the following (1) to (10), has the claw pole width a of the claw pole Xx residing on the rotating direction of the permanent rotor between the claw poles Xx, Yy of the each pair of claw poles formed to be larger than the claw pole width b of the claw pole Yy, and the claw pole pitch c from the claw pole Xx to the claw pole Yy formed to be smaller than the claw pole pitch d from the claw pole Yy to the claw pole Xx. Specifically, among the above a, b, c and d, it is determined to be a>b and c<d, and switching of the coil current is made at a positive peak of cogging torque curve or in its vicinity to be described afterward. (1) One claw pole Xx is retained as it is and the back part of the other claw pole Yy in the rotating direction is notched (see Fig. 5). In this case, a symbol Xx is given to a lower claw pole and a symbol Yy to an upper claw pole, hatched portions represent notched portions, and a row of magnets is indicated at the position of a stable point. The magnet (rotor) rotates to the left direction in the drawing. In the torque curve shown in the lower part, the solid line represents a cogging torque (torque due to attraction by the magnet and the stator yoke under the non-excited condition), the dotted line represents a generated torque (torque which is generated when current is supplied, and the sum of the cogging torque and the excited torque generated by the coil current), mark o represents a stable point, mark Δ represents an unstable point, and mark x represents a coil current switching point. As obvious from this torque curve, the distance e between the stable points shown on the left and the distance f between the stable points shown on the right are not equal (e<f), and there is a large positive peak on the right of the torque curve. The coil current is switched at this peak or in its vicinity (the same is applied to the following case). The excited torque (quantity obtained by subtracting the cogging torque shown by the solid line from the generated torque shown by the dotted line) is inverted by switching the coil current but, in this case shown in the drawing, the inverted quantity is very small as compared with the claw pole torque, so that no negative torque is generated and therefore no dead point is generated. In this torque curve, the absolute values at the peaks on both sides of the middle stable point of the claw pole torque curve are lower than the peaks near the right and left stable points. In other words, the inclines of the curve at the right and left stable points are greater than that at the middle stable point. In this sense, the middle stable point is a weak stable point and the right and left stable points are strong stable points. (2) In Fig. 6 claw pole Xx (referred to as the lower teeth) remain as they are and the front and back parts of the other claw pole Yy (referred to as the upper teeth) in the rotating direction are notched, but the back part is notched more than the front part. In this case, the characteristics are almost the same with the aforementioned (1). But, notching the front part of the claw pole Yy is not desirable because a drop of the cogging torque after the middle stable point is sharp in the torque curve of Fig. 6 (in other words, the middle stable point is emphasized). (3) In Fig. 7, the back part of the lower teeth (claw pole Xx) in the rotating direction of the rotor is increased and the upper teeth (claw pole Yy) remain as they are. In this case, since the width of the lower teeth is increased, the middle stable point is emphasized. And it is known that when the width of the lower teeth is increased, a torque in the positive direction of the rotating direction when switching has a tendency to be obtained with difficulty. (4) In Fig. 8, the back part of the lower teeth (claw pole Xx) in the rotating direction is increased and the back part of the upper teeth (claw pole Yy) in the rotating direction is notched. This is a combination of the aforementioned (1) and (3). (5) In Fig. 9, the back part of the lower teeth (claw pole Xx) in the rotating direction is increased and the front and back parts of the upper teeth (claw pole Yy) in the rotating direction are notched, but the back part of the upper teeth (claw pole Yy) is notched more than the front part. This is a combination of the aforementioned (2) and (3). (6) In Fig. 10, the front and back parts of the lower teeth in the rotating direction are increased and the upper teeth remain as they are, but the back part of the lower teeth is increased more than the front part. (7) In Fig. 11, the front and back parts of the lower teeth in the rotating direction are increased to the same extent and the back part of the upper teeth is notched. (8) In Fig. 12, the front and back parts of the lower teeth in the rotating direction are increased to the same extentand the front and back parts of the upper teeth in the rotating direction are notched, but the back part of the upper teeth is notched more than the front part. (9) In Fig. 13, the front and back parts of the lower teeth in the rotating direction are increased and the back part of the upper teeth in the rotating direction is notched, but the back of the upper teeth is increased more than the front part. 10) In Fig. 14, the front and back parts of the lower teeth in the rotating direction are increased and the front and back parts of the upper teeth in the rotating direction are notched, but the back of the lower teeth is increased more than the front part and the back of the upper teeth is notched further than the front part. It can be said in view of the aforementioned (1) to (10) that when the brushless DC motor has the above structure, intervals of the stable points and unstable points are unequal, differing from a conventional equal interval, and the generated torque cycle of the cogging torque is formed in large and small torque waves. And, it has been clarified that by switching the coil current at a high peak of absolute quantity or in the vicinity thereof among a plurality of positive peaks of the cogging torque, even if the excited torque is changed from positive to negative by changing the coil current, this is compensated by the positive cogging torque, so that the generation of the negative torque at a point where polarity is changed can be eliminated, resulting in preventing the generation of a dead point. In brief, the generated torque is equal to a cogging torque at a switching point of the coil current as shown in Fig. 15 and, therefore, the excited torque (the difference between the generated torque and the cogging torque) is zero. On the other hand, in an ordinary motor, the point zero of the excited torque agrees with the point zero of the cogging torque. It is known that too early switching of the coil current results in the state shown in Fig. 16 and too late switching results in the state shown in Fig. 17. That is to say, the advantage is provided that the excited torque is hardly converted into negative, by switching the coil current at a high peak of absolute quantity or in the vicinity thereof among a plurality of positive peaks of the cogging torque. As is obvious from Fig. 15, when the coil current is switched at the point where the excited torque is zero, the change in torque is smallest, so that it is preferable to switch the coil current at this position or in its vicinity. It should be noted that when the claw pole width is large, the torque at switching is likely to be negative, and when it is further increased the torque curve shown in Fig. 37 is generated. Fig. 18 shows that the coil current is switched at the vicinity of a positive peak of the cogging torque and no-current passing time is provided to switch the coil current. This example is different from a conventional control circuit and has a control circuit which can keep the no-current passing time at a prescribed level even if the voltage value of the detection signal of the Hall element changes. Fig. 19 is a diagram showing a two-phase unipolar type motor drive circuit using a no-current passing circuit. In this motor drive circuit, a differential amplifying circuit 22 for amplifying the output of a Hall element 21 consists of an operation amplifier OP1 and resistors R3 to R6, and the differential amplifying circuit 22 is branched into a peak hold circuit 23 which consists of an operation amplifier OP2, a diode D1 and a capacitor C1, and a comparison circuit 24 which consists of resistors R7, R8 and a comparator COMP1 on one hand, and an inversion amplifying circuit 25 which consists of an operation amplifier OP3 and resistors R9, R10, and a peak hold circuit 26 which consists of an operation amplifier OP4, a diode D2 and a capacitor C2, and a comparison circuit 27 which consists of resistors R11, R12 and a comparator COMP2 on the other hand, and they are connected to a drive circuit 28. Tr1 and Tr2 stand for transistors, L1 and L2 for coils of the motor, D3 and D4 for diodes. R1, R2, R13 to R16 for resistors. Vcc for a power source of the drive circuit, and VDD for a motor power source. And, Fig. 20 is a block diagram showing an A.L.C. (automatic level control) no-current passing circuit, and Fig. 21 is a drawing showing time charts of the no-current passing circuit. In this example, the output of the-Hall element 21 has noise components removed and signal components alone subjected to voltage amplification in the differential amplifying circuit 22 (see Fig. 21 (a)), peaks (VH) of the waveform on the plus side are held by the peak hold circuit 23 (see Fig. 21 (b)), and a transistor drive waveform having a no-current passing period is formed by the comparison circuit 24 (see Fig. 21 (c)). On the other hand, the waveform on the minus side is inverted by the inversion amplifying circuit 25, and a transistor drive waveform having a no-current passing period is formed by the peak hold circuit 26 and the comparison circuit 27 (see Fig. 21 (d), (e)). Therefore, according to the motor drive circuit of this example, since the comparison is always made at a predetermined ratio (VH/n, VL/n), the no-current passing period can be held at a certain level even if the voltage values VH, VL of the detected signal of the Hall element change. Thus, a no-current passing time is provided to switch the coil current and the coil current is switched in the vicinity of a positive peak of the cogging torque, so that the drop of torque due to switching as in a conventional case (see Fig. 37) can be prevented even if the switching point of the coil current is inaccurate due to assembly error in the production of the motor. And, the self-activation can be fully improved accordingly. Then, the inventors have made experiments on a self-activation characteristic by variously combining b/a values and c/d values at each a/p value among claw pole width a of claw pole Xx, claw pole width b of claw pole Yy, claw pole pitch c from the claw pole Xx to the claw pole Yy, claw pole pitch d from the claw pole Yy to the claw pole Xx, and pole pitch p (see Fig. 38) or among these a, b, c, d and p on the basis of the following motor specification. The results obtained are shown in Fig. 22 through Fig. 27. Motor specification: Motor structure: radial gap, outer rotor type Number of poles: 8 Motor outer diameter: 14.0 mm Motor height: 7.0 mm Gap: 0.5 mm Rotor magnet: ferrite magnet (BHmax1.4MGOe) In Fig. 22 through Fig. 27, mark o indicates that there is an activation torque (exceeding 0 gcm) and mark x indicates that there is no activation torque (0 gcm). And, the blank blocks on the left side indicate that the combination is dimensionally impossible. In Fig. 22, the ratio (a/p) of pole pitch p of the permanent magnet (see Fig. 38) and claw pole width a is 1.0. In this example, when b/a is 0.50 to 0.95, an activation torque is generated when c/d is 0.60 to 0.95. In Fig. 23, (a/p) is 0.95. In this example, when b/a is 0.50 to 0.95, an activation torque is generated when c/d is 0.56 to 0.91. In Fig. 24, (a/p) is 0.90. In this example, when b/a is 0.50 to 0.95, an activation torque is generated when c/d is 0.49 to 0.95. In Fig. 25, (a/p) is 0.85. In this example, when b/a is 0.50 to 0.95, an activation torque is generated when c/d is 0.47 to 0.95. In Fig. 26, (a/p) is 0.80. In this example, when b/a is 0.50 to 0.95, an activation torque is generated when c/d is 0.43 to 0.95. In Fig. 27, (a/p) is 0.75. In this example, when b/a is 0.50 to 0.95, an activation torque is generated when c/d is 0.39 to 0.90. When (a/p) is 0.7, a good result cannot be obtained. Therefore, (a/p) should exceed 0.7. Further, the inventors have measured the nonuniformity. of rotation by variously combining b/a values and c/d values on the basis of the aforementioned motor specification. To measure the nonuniformity of rotation, an optical encoder was attached to the motor, a constant velocity servo circuit was used, and value Vf represented by the following expression was used. Vf=(Δf/fc)*100% In the above expression, Δf stands for a variation of frequency of the servo voltage waveform (or a variation of speed), and fc for a carrier frequency of the encoder at a prescribed rpm. The results obtained are shown in Fig. 28 through Fig. 33. In Fig. 28 through Fig. 33, mark o ○ indicates that the nonuniformity of rotation is very slight, mark ο indicates that there is little nonuniformity of rotation, mark Δ indicates that there is appreciable nonuniformity of rotation, and mark x indicates that there is considerable nonuniformity of rotation. It has been found that the motor is practically usable when mark o ○ or ○ is given. In Fig. 28, a ratio (a/p) of pole pitch p of the permanent magnet and claw pole width a is 1.0. In this example, (1) when b/a is 0. 50 to 0. 90, and c/d is 0.60 to 0.95, and (2) when b/a is 0.50 to 0.85, and c/d is 0.60 to 1.00, motor rotation with less nonuniformity of rotation is obtained. In Fig. 29, (a/p) is 0.95. In this example, when b/a is 0.50 to 1.00, and c/d is 0.56 to 1.00, motor rotation with less nonuniformity of rotation is obtained. In Fig. 30. (a/p) is 0.90. In this example, (1) when b/a is 0.50 to 1.00, and c/d is 0. 78 to 1. 00, (2) when b/a is 0.55 to 1. 00, and c/d is 0.62 to 1.00. (3) when b/a is 0.60 to 1.00, and c/d is 0.59 to 1.00, and (4) when b/a is 0.65 to 1.00, and c/d is 0.57 to 1.00, motor rotation with less nonuniformity of rotation is obtained. In Fig. 31, (a/p) is 0.85. In this example, (1) when b/a is 0.50 to 1.00, and c/d is 0.95 to 1.00, (2) when b/a is 0.55 to 1.00, and c/d is 0.80 to 1.00, (3) when b/a is 0.60 to 1.00, and c/d is 0.62 to 1.00, and (4) when b/a is 0.65 to 1.00, and c/d is 0.54 to 1.00, motor rotation with less nonuniformity of rotation is obtained. In Fig. 32, (a/p) is 0.80. In this example, (1) when b/a is 0.50 to 1.00, and c/d is 0.90. (2) when b/a is 0.50 to 0.90, and c/d is 0.90 to 1.00. (3) when b/a is 0.55 to 1.00, and c/d is 0.85 to 0.90 (4) when b/a is 0.55 to 0.90, and c/d is 0.85 to 1.00, (5) when b/a is 0.60 to 1.00, and c/d is 0.67 to 0.90. (6) when b/a is 0.60 to 0.90, and c/d is 0.67 to 1.00, (7) when b/a is 0.65 to 1.00, and c/d is 0.49 to 0.90, and (8) when b/a is 0.65 to 0.90, and c/d is 0.49 to 1.00, motor rotation with less nonuniformity of rotation is obtained. In Fig. 33, a/p) is 0.75. In this example, (1) when b/a is 0.50 to 1.00, and c/d is 0.80 to 1.00, (2) when b/a is 0.55 to 1.00, and c/d is 0.75 to 1.00, (3) when b/a is 0.60 to 1.00, and c/d is 0.60 to 1.00, (4) when b/a is 0.65 to 1.00, and c/d is 0.53 to 1.00, and (5) when b/a is 0.70 to 1.00, and c/d is 0.47 to 1.00, motor rotation with less nonuniformity of rotation is obtained. When (a/p) is 0.70, a good result cannot be obtained. Therefore, (a/p) should exceed 0.7. Reasons why a motor rotation which is possible to make self-activated and has less nonuniformity of rotation can be obtained are as follows. In the case where (a/p) is 1.0, when b/a is 0.50 to 0.90 and c/d is 0.60 to 0.95, a motor rotation which is possible to make self-activated and has less nonuniformity of rotation can be obtained. In the case where (a/p) is 0.95, when b/a is 0.50 to 0.95 and c/d is 0.56 to 0.91, a motor rotation which is possible to make self-activated and has less nonuniformity of rotation can be obtained. In the case where (a/p) is 0.90, (1) when b/a is 0.50 to 1.00 and c/d is 0.78 to 0.95, (2) when b/a is 0.55 to 0.95 and c/d is 0.62 to 0.95, (3) when b/a is 0. 60 to 0.95 and c/d is 0.59 to 0.95, and (4) when b/a is 0.65 to 0.95 and c/d is 0.57 to 0.95, motor rotation which is possible to make self-activated and has less nonuniformity of rotation can be obtained. In the case where (a/p) is 0.85, (1) when b/a is 0.50 to 0.95 and c/d is 0.95 to 0.95, (2) when b/a is 0.55 to 0.95 and c/d is 0.80 to 0.95, (3) when b/a is 0.60 to 0.95 and c/d is 0.62 to 0.95, and (4) when b/a is 0.65 to 0.95 and c/d is 0.54 to 0.95, motor rotation which is possible to make self-activated and has less nonuniformity of rotation can be obtained. In the case where (a/p) is 0.80, (1) when b/a is 0.50 to 0.95 and c/d is 0.90, (2) when b/a is 0.50 to 0.90 and c/d is 0.90 to 0.95, (3) when b/a is 0.55 to 0.95 and c/d is 0.85 to 0.90, (4) when b/a is 0.55 to 0.90 and c/d is 0.85 to 0.95, (5) when b/a is 0.60 to 0.95 and c/d is 0.67 to 0.90, (6) when b/a is 0.60 to 0.90 and c/d is 0.67 to 0.95, (7) when b/a is 0.65 to 0.95 and c/d is 0.49 to 0.90, and (8) when b/a is 0.65 to 0.90 and c/d is 0.49 to 0.95, motor rotation which is possible to make self-activated and has less nonuniformity of rotation can be obtained. In the case where (a/p) is 0.75, (1) when b/a is 0.50 to 0.95 and c/d is 0.80 to 0.90, (2) when b/a is 0.55 to 0.95 and c/d is 0.75 to 0.90, (3) when b/a is 0.65 to 0.95 and c/d is 0.60 to 0.90, (4) when b/a is 0.65 to 0.95 and c/d is 0.53 to 0.90, and (5) when b/a is 0.70 to 0.95 and c/d is 0.47 to 0.90, motor rotation which is possible to make self-activated and has less nonuniformity of rotation can be obtained. Although the examples have been described in connection with an outer rotor type motor with a ferrite magnet, this invention is not limited such a motor, and may be applied to an inner rotor type motor and another motor using another magnet. And, in addition to the single-phase bipolar drive used in the examples, two-phase, three-phase, ... unipolar drives to which this invention can be applied are covered by this invention. Further, in the aforementioned examples, the rotor position is detected with the Hall element, but this invention can be applied to another sensor drive other than the Hall element and to a so-called sensorless drive which does not use a sensor and switches the coil current by detecting the rotor position by back electromotive force for example. The brushless DC motor described can improve the self-starting reliability by a relatively simple structure and can obtain a motor structure capable of lowering the rotational speed fluctuation and a method for driving a motor, so that it can be suitable to compact disk players, all sorts of audio equipment, and OA equipment which requires accurate rotation.

Claims: A brushless DC motor comprising a cylindrical or segment shaped permanent magnet rotor (2) which has N and S poles alternately magnetized at an equal pole pitch p in the circumferential direction, a stator (10) consisting of two stator yokes (X,Y) disposed to oppose to each other, each stator yoke having a soft magnetic metal plate folded to form a set of claw poles (Xx,Yy) half in number of the number of poles of said permanent magnet rotor, said stator being made by combining these claw poles, and a cylindrical coil (12) which is positioned between the stator yokes and excites said stator, wherein two adjacent claw poles, one from each set (Xx,Yy ...), form a pair (R) of claw poles, of the two claw poles (Xx,Yy) of each pole pair the width a of one claw pole (Xx) located in the leading position with respect to the direction of rotation of the rotor (2) is formed to be larger than the width b of the other claw pole (Yy) of the pair which occupies the trailing position, the claw pole pitches c,d,c,d, ... connecting the midpoints of each claw pole (Xx,Yy ...) are such that the claw pole pitch c from the said one claw pole (Xx) to the other claw pole (Yy) of the pair is formed to be equal to or smaller than the claw pole pitch d from the said other claw pole (Yy) to the adjacent one claw pole (Xx)in the trailing direction with respect to rotor rotation, characterized by setting the ratio (a/p) of the claw pole width a and the pole pitch p, the ratio (b/a) of the claw pole width a and the claw pole width b, and the ratio (c/d) of the claw pole pitch c and the claw pole pitch d to fall in any of the following ranges: in the case where (a/p) is 1.0, (1) when (b/a) is 0.55 to 0.90, (c/d) is 0.63 to 0.95, or (2) when (b/a) is 0.55 to 0.85, (c/d) is 0.63 to 1.00, in the case where (a/p) is 0.95, when 0.55 ≤ (b/a) < 1.00, (c/d) is 0.59 to 1.00, in the case where (a/p) is 0.90, (1) when 0.55 ≤ (b/a) < 1.00, (c/d) is 0.62 to 1.00, (2) when 0.60 ≤ (b/a) < 1.00, (c/d) is 0.59 to 1.00, or (3) when 0.65 ≤ (b/a) < 1.00, (c/d) is 0.57 to 1.00, in the case where (a/p) is 0.85, (1) when 0.55 ≤ (b/a) < 1.00, (c/d) is 0.80 to 1.00, (2) when 0.60 ≤ (b/a) < 1.00, (c/d) is 0.62 to 1.00, or (3) when 0.65 ≤ (b/a) < 1.00, (c/d) is 0.54 to 1.00, in the case where (a/p) is 0.80, (1) when 0.55 ≤ (b/a) < 1.00, (c/d) is 0.85 to 0.90, (2) when (b/a) is 0.55 to 0.90, (c/d) is 0.85 to 1.00, (3) when 0.60 ≤ (b/a) < 1.00, (c/d) is 0.67 to 0.90, (4) when (b/a) is 0.60 to 0.90, (c/d) is 0.67 to 1.00, (5) when 0.65 ≤ (b/a) < 1.00, (c/d) is 0.49 to 0.90, or (6) when (b/a) is 0.65 to 0.90, (c/d) is 0.49 to 1.00, in the case where (a/p) is 0.75, (1) when 0.55 ≤ (b/a) < 1.00, (c/d) is 0.75 to 1.00, (2) when 0.60 ≤ (b/a) < 1.00, (c/d) is 0.60 to 1.00, (3) when 0.65 ≤ (b/a) < 1.00, (c/d) is 0.53 to 1.00, or (4) when 0.70 ≤ (b/a) < 1.00, (c/d) is 0.47 to 1.00, whereby to achieve uniformity in rotational speed. A brushless DC motor comprising a cylindrical or segment shaped permanent magnet rotor (2) which has N and S poles alternately magnetised at an equal pole pitch p in the circumferential direction, a stator (10) consisting of two stator yokes (X,Y) disposed to oppose to each other, each stator yoke having a soft magnetic metal plate folded to form a set of claw poles (Xx,Yy) half in number of the number of poles of said permanent magnet rotor, said stator being made by combining these claw poles, and a cylindrical coil (12) which is positioned between the stator yokes and excites said stator, wherein two adjacent claw poles, one from each set (Xx, Yy ... ) , form a pair (R) of claw poles, of the two claw poles (Xx,Yy) of each pole pair the width a of one claw pole (Xx) located in the leading position with respect to the direction of rotation of the rotor (2) is formed to be larger than the width b of the other claw pole (Yy) of the pair which occupies the trailing position; the claw pole pitches c,d,c,d, ... connecting the midpoints of each claw pole (Xx,Yy ...) are such that the claw pole pitch c from the said one claw pole (Xx) to the other claw pole (Yy)of the pair is formed to be smaller than the claw pole pitch d from the said other claw pole (Yy) to the adjacent one claw pole (Xx)in the trailing direction with respect to rotor rotation, characterized by setting the ratio (a/p) of the claw pole width a and the pole pitch p, the ratio (b/a) of the claw pole width a and the claw pole width b, and the ratio (c/d) of the claw pole pitch c and the claw pole pitch d to fall in any of the following ranges: in the case where (a/p) is 1.0, (b/a) is 0.55 to 0.90 and (c/d) is 0.63 to 0.95, in the case where (a/p) is 0.95, (b/a) is 0.55 to 0.95 and (c/d) is 0.59 to 0.91, in the case where (a/p) is 0.90, (1) when (b/a) is 0.55 to 0.95, (c/d) is 0.62 to 0.95, (2) when (b/a) is 0.60 to 0.95, (c/d) is 0.59 to 0.95, or (3) when (b/a) is 0.65 to 0.95, (c/d) is 0.57 to 0.95, in the case where (a/p) is 0.85, (1) when (b/a) is 0.55 to 0.95, (c/d) is 0.80 to 0.95, (2) when (b/a) is 0.60 to 0.95, (c/d) is 0.62 to 0.95, or (3) when (b/a) is 0.65 to 0.95, (c/d) is 0.54 to 0.95, in the case where (a/p) is 0.80, (1) when (b/a) is 0.55 to 0.95, (c/d) is 0.85 to 0.90, (2) when (b/a) is 0.55 to 0.90, (c/d) is 0.85 to 0.95, (3) when (b/a) is 0.60 to 0.95, (c/d) is 0.67 to 0.90, (4) when (b/a) is 0.60 to 0.90, (c/d) is 0.67 to 0.95, (5) when (b/a) is 0.65 to 0.95, (c/d) is 0.49 to 0.90, or (6) when (b/a) is 0.65 to 0.90, (c/d) is 0.49 to 0.95, in the case where (a/p) is 0.75, (1) when (b/a) is 0.55 to 0.95, (c/d) is 0.75 to 0.90, (2) when (b/a) is 0.60 to 0.95, (c/d) is 0.60 to 0.90, (3) when (b/a) is 0.65 to 0.95, (c/d) is 0.53 to 0.90, or (4) when (b/a) is 0.70 to 0.95, (c/d) is 0.47 to 0.90, whereby to achieve self-starting reliability and uniformity in rotational speed.

Inventors: ITO NORIO, MATSUZAWA KINYA, MIYAZAWA HIROSHI, ITO, NORIO, MATSUZAWA, KINYA, MIYAZAWA, HIROSHI
Applicants: SEIKO EPSON CORP, SEIKO EPSON CORPORATION
Application year: 1993
Main classification: H02K29
IPC codes: H02K29, H02P6