Motor structure

Abstract: This invention is to provide a motor structure in a salient pole type DC motor in which torque ripple and cogging torque are reduced without deceasing the efficiency and the torque constant, and hence the irregularity of the rotation is reduced. The magnetic flux density distribution of an air gap is more approached to a sine wave shape by forming a groove or a slit in the vicinity of the neutral part (a boundary of an N-pole and an S-pole) of a rotor magnet in the length of the air gap formed in a radial direction of the rotor magnet and a stator core of a salient pole type DC motor.

Description: This invention relates to a motor structure in a salient pole type DC motor in which a cogging torque and a torque ripple are reduced without decreasing the efficiency and a torque constant and hence the irregularity of rotation is reduced. In earlier methods for reducing the irregularity of a torque or rotation, there is a known device in which switching is conducted in a (2n + 1) phase, the ratio of the number of the poles of a rotor magnet to the number of salient poles wound with the winding of a stator core is (2n + 2) : (2n + 1), and the phase currents of the stator windings are sequentially switched in response to the rotating position, as for example, disclosed in Japanese Patent Publication laid-open No. 49-8568. In this method, the amount of cogging torque becomes the lowest common multiple of the number of the stator windings and the number of the poles of the rotor magnet, and as the amount of the cogging torque per one revolution is increased, the apparent value is felt to be small, but does not become "0". Accordingly, in the case of a motor which is used at a low speed so that the irregularity of its rotation becomes a problem, for example a record player turntable drive motor or a floppy disk spindle motor, a method of providing an interpole at the stator, and of forming a slot pitch which is irregular or the shape of a salient pole piece, can be used together. However, although these methods can reduce the irregularity of the torque, they have the disadvantages that the motor efficiency and the torque constant are also decreased. Alternatively, as to the method of forming grooves or slits on a rotor magnet, there is a method described in "Brushless DC motor and rotor magnet thereof" of Japanese Patent Application laid-open No. 1-318536 filed by the same inventors as this application. This prior invention is a motor comprising: 1) a stator having salient poles wound with windings and interpoles wound without windings, 2) one rotor pole detecting means applied to a brushless DC motor, and 3) the number of grooves or slits being half the number of the poles. This invention has features that 1) the starting torque is stabilized, and 2) the motor efficiency is improved. The prior invention is fundamentally different from this invention. JP-A-6158456 discloses a motor structure having a rotor magnet, a stator core and a magnetic groove. EP-A-433479 discloses a brushless DC motor and its rotor magnet. According to the present invention, there is provided a motor structure in a motor comprising: a rotor magnet; a stator core; an air gap formed between the rotor magnet and the stator core in a radial direction in such a manner that said stator structure is a salient pole type; and a magnetic groove or a slit formed in the vicinity of a neutral part (a boundary between an N pole and an S pole) of said rotor magnet side so that the magnetic flux density change of said air gap is close to a sine wave state as compared with that of said air gap of a constant length; characterised in that the width (as seen from a central angle) of said groove or said slit in said magnet is, when the least common multiple of the number of the poles of said rotor magnet and the number of the salient poles wound with the winding of said stator core is N, a value near 360/N°. According to this invention, the groove or the slit which generates the magnetic change is formed in the rotor magnet, and the magnetic flux density distribution in the air gap is much closer to the sine wave shape. Accordingly, the torque ripple is reduced without decreasing the motor efficiency and the torque constant. As a result, the irregularity of the rotation can be greatly reduced. In the accompanying drawings: Fig. 1 is an exploded perspective view showing the essential portion of a motor applied to a three-phase brushless DC spindle motor of a flat radial air gap type; Fig. 2 is a perspective view showing a rotor assembly 2; Fig. 3 is a perspective view showing a rotor magnet 9; Fig. 4 is a sectional view showing the rotor magnet 9; Fig. 5 is a view of the principle of a 3-phase brushless DC motor according to this invention; Fig. 6 is a plane view showing the detail of the rotor magnet; Fig. 7 is a plane view showing the surface magnetic flux density distribution of the rotor magnet; Fig. 8 is a partial flat view showing another embodiment of the rotor magnet; Fig. 9 is a plane view showing still another embodiment of the rotor magnet; and Fig. 10 is a flat view showing the still another embodiment of the rotor magnet. An embodiment of this invention will be described in detail with reference to the accompanying drawings. Fig. 1 is an exploded perspective view showing the essential portion of the motor in which this invention is applied to a three-phase brushless DC spindle motor of a flat radial air gap type. In Fig. 1, numeral 1 denotes a housing made from aluminum. Bearings 3 (two pieces) for rotatably supporting a rotor assembly 2 are contained in the housing 1. A stator assembly 4 (described later) and a driving circuit plate 5 (described later) are fixed to the housing 1. Mounting holes 6 are provided to fix a complete motor unit to a frame such as FDD (Floppy Disk Driver) which is also in the housing 1. The driving circuit plate 5 is formed of a soft iron plate. An insulating film is provided on the surface of the driving circuit plate 5. A printed circuit is provided on the surface of the insulating film. Electronic components such as an integrated circuit necessary to drive the three-phase brushless DC motor, three rotor position detectors, resistors, capacitors, etc., are mounted on the plate 5. An electric circuit necessary to drive the motor is provided. An FG (Frequency Generator) pattern coil for sensing the rotating speed of the rotor is also printed on it. Twelve radial stator salient poles 4' are formed in the stator assembly 4. A plurality of magnetic steel sheets punched by a press are laminated and stacked in a rotational shaft direction. The stator assembly 4 is insulated at necessary positions and wound. Stator yoke set screws 7 (three pieces) are used to clamp the driving circuit plate 5 and the stator assembly 4. The rotor assembly 2 is formed by adhering a rotor magnet 9 to the inner periphery of a rotor yoke 8 made of a ferromagnetic material, and is clamped to a shaft 11 by using a rotor set screw 10. Thus, the rotor assembly 2 is attached to the shaft 11, and is rotatably supported by two ball bearings 3 inserted to the grooves of the housing 1. The operation of the motor is the same as a general three-phase bipolar driving system using three rotor pole detectors, and hence the description thereof will be omitted. The shape of the rotor magnet 9 according to this invention will be described in detail by referring to Figs. 2, 3 and 4. Fig. 2 is a perspective view showing the rotor assembly 2. As described above, the rotor assembly 2 has the rotor yoke 8 made of a ferromagnetic material and the rotor magnet 9 adhered to the inner periphery of the rotor yoke 8, and also has an index magnet 12 mounted at an arbitrary position of the outer periphery of the rotor yoke 8. Fig. 3 is a perspective view showing the rotor magnet 9. The rotor magnet 9 has two parts, a FG (Frequency Generator) magnet part A to be operated with the FG pattern coil (not shown in Fig. 1) printed on the driving circuit plate 5, and a main magnet part B for generating a torque as a motor. Fig. 4 is a sectional view showing the magnetizing directions of the FG magnet parts A and the main magnet parts B of the rotor magnet 9. The magnetizing direction of the FG magnet part A is an axial direction (a direction perpendicularly crossing the FG pattern coil), and the magnetizing direction of the main magnet part B is a radial direction (a direction perpendicularly crossing the stator coil). The motor according to this invention is a salient pole type motor having an air gap in a radial direction and a laminated stator core structure in such a manner that the length of an air gap formed of the rotor magnet and the stator core is varied in the vicinity of the neutral part (a boundary of an N-pole and an S-pole) of the rotor magnet. A groove or a slit is formed at the neutral part of the rotor magnet such that the magnetic flux density distribution in the air gap closely resembles a sine wave shape. As a result, the cogging torque and the torque ripple are reduced without decreasing the motor efficiency and the torque constant, and the mo tor having a small irregularity of rotation can be provided. Fig. 5 is a principle view of a three phase brushless DC motor, illustrating an example of an outer rotor type having sixteen rotor magnet poles and twelve salient poles wound with the windings of the stator core. In Fig. 5, symbols 4a to 41 denote stator poles; 4ca to 4cl, stator coils; and 13, 14, 15, rotor pole detectors. The stator assembly 4 has twelve stator poles 4a to 41 uniformly distributed at a central angle of 30° and twelve stator coils 4ca to 4cl are respectively wound on the stator poles. The three rotor pole detectors 13, 14, and 15 are magnetoelectric transducers, such as, for example, Hall elements, etc. The positions of the rotor pole detectors 13, 14, 15 are provided at substantially intermediate positions between the stator poles 4d and 4h, between the stator poles 4h and 41, and between the stator poles 41 and 4a, and hence the positions which can firmly detect the poles of the rotor magnets 9 via the air gap. The detail of the rotor magnet 9 is shown in Fig. 6, and the surface magnetic flux density distribution of the rotor magnet 9 is shown in Fig. 7. The FG magnetized part (the part A of Figs. 3 and 4) magnetized at a low level integrally with the rotor magnet end face (corresponding to the lower surface in Figs. 5 and 6) in Figs. 5 and 6 is not related to the description of the principle of this invention, and hence the description will be omitted. In Fig. 6, the rotor magnet 9 has sixteen magnetized poles, and has the same magnetic grooves as the sixteen poles 2a to 2p. All the positions of the grooves of this embodiment are located at the pole switching points (neutral points). The angle of each groove between the pole switching points is , where /2 is in the N-pole and /2 is in the S-pole. The surface magnetic flux density of the rotor magnet 9 becomes as shown in Fig. 7 due to the presence of such magnetic grooves 2a to 2p. That is, the surface magnetic flux density of the grooves 2a to 2p is greatly reduced as compared with the other parts, and is closer to the distribution of the sine wave shape as compared with the case which has no grooves. The feature of this invention is that the grooves or the slits to generate a magnetic change are formed in the rotor magnet and hence the magnetic flux density distribution in the air gap is closer to the sine wave shape. From this feature, the torque ripple is reduced without decreasing the motor efficiency and the torque constant. As a result, the irregularity of the rotation can be kept to a minimum. The influences of the angle or width and the depth of the grooves of the rotor magnet on the motor characteristics of this invention have been tested and are discussed here. In the experiments, the structure of the stator was kept constant. The results of measuring the motor voltage, the load torque, the motor current, the motor efficiency, the torque constant and the irregularity of the rotation in three cases when the angles  of the grooves 2a to 2p of the rotor magnet 9 shown in Fig. 6 are 0°, 7.5° and 11.25°, were measured and are shown in Table 1. However, the depth of all the grooves (T1 to T2 of Fig. 6) is 0.25 mm, which is the same value as the length of the air gap. Depth of groove of 0.25 mm Prior Art This Invention Characteristics =0 =360/N=7.5 =360/2P=11.25 Motor voltage (V) 5 5 5 Motor load torque (g-cm) 40 40 40 Motor current (A) 0.152 0.150 0.158 Motor efficiency (%) 16.2 16.4 15.6 Torque constant (gcm/A) 401 401 378 Irregular rotation (%) 0.193 0.150 0.190 N = lowest common multiple of number of rotor poles and number of salient poles wound with windings of stator core (N = 48 in the example of Fig. 5) P = number of rotor poles. The result of the similar experiments conducted by setting the depth of the groove to 0.5 mm (double the length of the air gap) is shown in Table 2. Depth of groove of 0.50 mm Prior Art This Invention Characteristics =0 =360/N=7.5 =360/2P=11.25 Motor voltage (V) 5 5 5 Motor load torque (g-cm) 40 40 40 Motor current (A) 0.152 0.153 0.159 Motor efficiency (%) 16.2 16.1 15.5 Torque constant (gcm/A) 402 398 379 Irregular rotation (%) 0.193 0.180 0.192 As understood from the Tables 1 and 2, the irregularity of the rotation can be reduced without decreasing the motor efficiency and the torque constant by suitably selecting the width of the grooves of the rotor magnet and the depth of the grooves. It is also understood to be effective by setting to the groove width =360/N=7.5° ( 1 / 3 of the pole) and the depth of the groove T1 - T2 = 0.25 mm (the same value as the air gap). The sectional shape of the groove formed on the rotor magnet is not limited only to the rectangular shape, but may be as shown by A to E in Fig. 8. Example A of Fig. 8 is a V-groove structure and B is a semicircular shape. As shown by example C in Fig. 8, both sides of the bottom of the groove may be rounded or both sides of the bottom of the groove may be bitten from a central angle  as in example D. Further, as shown by example E in Fig. 8, the centre of the groove may be extended toward the opposed surface of the stator. The sectional shape of the groove may be suitably modified within the scope of this invention. The structure of the rotor magnet may be also different. Figs. 9 and 10 show examples of the different rotor magnets. To improve the characteristics, the rotor magnet may be formed of a high performance magnet such as a sintered magnet or a rare earth element magnet. However, when the entire rotor magnet is manufactured by the sintered magnet or the rare earth element magnet, it becomes expensive. Accordingly, in the embodiment shown in Fig. 9, only necessary portions are formed from high performance magnets 100, like the sintered magnets or the rare earth element magnets, and the other parts are formed of a low cost plastic magnet 101 which can be easily molded in a desired shape. Thus, equivalent magnetic groove is formed, and a rotor magnet having high performance and low cost is obtained. Since the groove of the rotor magnet becomes thin, it is weak in strength, easily deformed, and must be carefully handled. The example shown in Fig. 10 is strengthened by filling the groove of a rotor magnet 102 with a suitable reinforcing material 103. As the reinforcing material 103, for example, a nonmagnetic plastic material is employed. When the rotor magnet 102 is formed of the high performance magnet such as the sintered magnet or the rare earth element magnet, a plastic magnet having low performance may be employed as the reinforcing material 103. The groove or the slit in the rotor magnet in which the FG magnet part A and the main magnet part B shown in Fig. 4 are integrally formed may only be in the main magnet part B, or may also extend into the FG magnet part A. The reason why is because the sufficient effect can be obtained by the degree that the depth of the groove is the length of the air gap (normally about 0.2 to 0.4mm), sufficiently smaller than the width of the magnetized surface of the FG magnet, and hence the influence of the FG magnet is so small as to be ignored. The embodiments of this invention have been described in detail. However, this invention is not limited only to the structures of the embodiments. The embodiment is of the outer rotor type motor. However, this invention may also be applied to an inner rotor type. Further, a motor having a small irregularity in the rotation is also obtained by the similar method and is not dependent upon the driving type or the number of the poles of the magnet. Various modifications may also be provided in the components formed of the materials of the magnet and the reinforcing material. Further, in addition to the method of detecting the rotor position by the magnetoelectric transducer, this invention may also be applied to a method of detecting the rotor position by an optical device. With the above invention, the motor torque ripple and the cogging torque is reduced without decreasing the motor efficiency and the torque constant, and even at the time of low rotation, a motor having only a small irregularity in the rotation can be provided. Particularly recently, a linear drive tape using the output waveform of a rotor position detector is employed as a drive system for suppressing the generation of a switching noise at the time of commutating, and hence the device of this invention for obtaining the sine wave is very effective in this arrangement.

Claims: A motor structure in a motor comprising: a rotor magnet (9); a stator core (4); an air gap formed between the rotor magnet and the stator core in a radial direction in such a manner that said stator structure is a salient pole type; and a magnetic groove (2a to 2p) or a slit formed in the vicinity of a neutral part (a boundary between an N pole and an S pole) of said rotor magnet side so that the magnetic flux density change of said air gap is close to a sine wave state as compared with that of said air gap of a constant length; characterised in that the width (as seen from a central angle) of said groove (2a to 2p) or said slit in said magnet (9) is, when the least common multiple of the number of the poles of said rotor magnet and the number of the salient poles wound with the winding of said stator core (4) is N, a value near 360/N°. A motor structure according to claim 1, wherein said stator core (4) has no interpole and the pitch of salient poles divided in a circumferential direction is uniform. A motor structure according to claim 1, wherein the number of said grooves (2a to 2p) or said slits in said rotor magnet (9) are equal to the number of the poles of said rotor magnet. A motor structure according to claim 3, wherein the deepest depth of said groove (2a to 2p) or said slit is substantially equal to the length of said air gap.

Inventors: FUJITANI SAKAE, SUZUKI YUZURU, FUJITANI, SAKAE, SUZUKI, YUZURU
Applicants: MINEBEA KK, MINEBEA CO.,LTD.
Application year: 1996
Main classification: H02K29
IPC codes: H02K21, H02K29, H02K37, H02K1