Specializing in the design and manufacture of automotive motor armatures and stators.

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Get to know brushless DC motor stators and rotors in one minute

Release Time:

2023-03-01

   Brushless motor stator and rotor These are parts of a motor. The two parts can cooperate with each other through the action of the magnetic coil to convert electromagnetic energy information into mechanical energy.

  In simple terms, the stator and rotor of a brushless motor are the rotating parts of the motor. Brushless DC motors use semiconductor switching devices to achieve electronic commutation, that is, electronic switching devices replace traditional contact commutators and brushes. It has the advantages of high reliability, no commutation sparks, and low mechanical noise, and is widely used in high-end tape recorders, video recorders, electronic instruments, and automated office equipment.

  A brushless DC motor consists of a permanent magnet rotor, a multi-pole winding stator, and a position sensor. The position sensor detects the change in the rotor position and switches the current of the stator windings in a certain order (that is, it detects the position of the rotor magnetic pole relative to the stator windings, and generates a position sensing signal at a certain position, which is processed by the signal conversion circuit to control the power switching circuit, and switches the winding current according to a certain logical relationship). The working voltage of the stator winding is provided by the electronic switching circuit controlled by the position sensor output.

  There are three types of brushless motor stator and rotor position sensors: photoelectric, magnetoresistive, and electromagnetic.

  In a brushless DC motor using a magnetoresistive position sensor, the magnetoresistive sensor (such as a Hall element, magnetoresistive diode, magnetoresistive triode, magnetoresistive resistor, or special integrated circuit) is mounted on the stator assembly to detect the change in the magnetic field generated when the permanent magnet rotor rotates.

  In a brushless DC motor with a photoelectric position sensor, a photoelectric sensing device is installed at a certain position on the stator assembly, and a light-shielding plate is installed on the rotor. The light source is a light-emitting diode or a small bulb. When the rotor rotates, the photosensitive element on the stator will intermittently generate a pulse signal of a certain frequency due to the action of the light-shielding plate. In a brushless DC motor using an electromagnetic position sensor, an electromagnetic sensor component is installed on the stator assembly. When the position of the permanent magnet rotor changes, the electromagnetic effect will cause the electromagnetic sensor to generate a high-frequency modulated signal (its amplitude changes with the change of the rotor position).


Brushless motor stator and rotor

09-13

2022

Methods for winding the armature of a DC brushless automotive motor

The method for winding the armature winding of a DC brushless car motor is to leave a section of the cable end free and tie it tightly to the shaft. Hold the car armature with one hand, and wind the coil inductance clockwise with the other hand. Taking a five-slot armature as an example, the first coil is 1-5, the second coil is 2-6, then 3-7..., and so on. The sides of many components are on the next layer. The 5-9 components have one side on the next layer and the other side on the top layer. The sides of many components are on the top layer. In order to ensure the insulation between the top layer and the next layer components, it is advisable to place 0.1-0.15mm thick insulating paper pads in between. When the coil inductance in the slot reaches a certain level, a crossbar is needed to make it reach the bottom of the slot. When winding the coil inductance, the wire should be tightened first. Whether in the slot or the wire connection part, it is necessary to prevent the occurrence of crossed turns to prevent excessive space occupation and short circuit between turns due to partial stress of the wire. After all the windings are wound, the wire ends of the same winding component are bundled together, then the insulation layer of the wire connector is removed, different color waterproof sleeves are used, and they are embedded in the corresponding commutator segments. The important role of the armature in a DC brushless motor: DC motor,

08-22

2022

Design rules for automotive armatures

Automotive armature manufacturers indicate that single-layer windings are not suitable for large-capacity motors, and small-capacity motors should not be double-layered. The magnetic flux density of the motor core should not be too high or too low. When the frequency and thickness of the silicon steel sheet core material are constant, the iron loss depends on the magnetic flux density. If the magnetic flux density is too high, the iron loss increases, and the motor efficiency decreases. The increased heat from the iron core increases the motor temperature, and the increased excitation power increases the motor power factor, so the magnetic flux density of the core should not be too high. Try to avoid excessive saturation of the magnetization curve. If the magnetic density is too low, it will increase the amount of motor material used, increasing the cost. The rotor teeth are narrow, the magnetic density is high, the slot entry wire is large, that is, the automotive armature slots are large. Automotive armature manufacturers indicate that due to poor air conduction, there are many gaps in the slots, affecting the coils and easily damaging the heat dissipation of the insulation material, accelerating the increase in motor temperature. The slot fill factor of the motor slots cannot be too high or too low. Usually, the slot fill factor for low-speed motors is 75% to 85%, which can effectively prevent the enamelled wire from loosening in the slots. The design of the motor rotor slot shape should use parallel trapezoidal recesses as much as possible, and the edges of the recesses should not have sharp corners. Try to use a circular bottom recess, because the circular slot is filled with aluminum, which is easy to injection mold and the stator chip is easy to insert. The coil current density should not be...

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