ROTOR POSITION SENSOR SYSTEM FOR A SLOTLESS MOTOR

Abstract

The present invention relates to a slotless motor comprising a rotor position sensing element. The motor has a rotor having a rotational axis and a plurality of coil windings arranged into an integer N number of distinct blocks, each block being arranged about the rotational axis and having a gap between each adjacent pair of blocks. The rotor position element has a sensor ring having a sensor fixed to the sensor ring and a sensor ring attachment extending from the sensor ring wherein the sensors are spaced around the rotational axis and wherein the rotor position sensing element is configured to hold the sensor ring relative to at least one of the blocks such that the sensor is held in a predetermined position.

Claims

1. A slotless motor comprising: a flux ring; a rotor having a rotational axis; a plurality of coil windings arranged into an integer N number of distinct blocks, each block being arranged about the rotational axis and having a gap between each adjacent pair of blocks; and a rotor position sensing element comprising: a sensor ring having a sensor fixed to the sensor ring; and a sensor ring attachment extending from the sensor ring; wherein the sensors are spaced around the rotational axis; and wherein the rotor position sensing element is configured to hold the sensor ring relative to at least one of the blocks such that the sensor is held in a predetermined position.

2. The motor of claim 1, wherein the sensor ring attachment couples the sensor ring to one of the gaps between adjacent blocks.

3. The motor of claim 1, further comprising a motor housing, wherein the housing holds the coil windings in a fixed location relative to the housing.

4. The motor of claim 3, wherein the sensor ring is coupled to the motor housing.

5. The motor of claim 3, wherein the sensor ring is integrally formed with the motor housing.

6. The motor of claim 3, wherein the motor housing is made of a metal.

7. A rotor position sensing element for a slotless motor comprising a rotor having a rotational axis and a plurality of coil windings wherein the coil windings are arranged into N distinct blocks of coil windings having a gap between each pair of adjacent blocks, the rotor position sensing element comprising: a sensor ring comprising at least one sensor fixed to the sensor ring and configured to be spaced around the rotational axis; and a sensor ring attachment extending from the sensor ring and configured to hold the sensor ring relative to at least one of the blocks such that the at least one sensor is held in position relative to the blocks.

8. The motor of claim 1, wherein the sensor is any one of: a magnetic field sensor, a potentiometric position sensor, an inductive position sensor, an eddy current-based position sensor, a capacitive position sensor, a fibre-optic position sensor, an optical position sensor and an ultrasonic position sensor.

9. The motor of claim 1, wherein the rotor position sensing element comprises a plurality of sensors including the sensor.

10. The motor of claim 9, wherein the plurality of sensors is angularly spaced apart around the rotational axis based on one or more of the number(s) of distinct blocks and/or a number of phases of the coil windings.

11. The motor of claim 1, wherein the sensor ring and the sensor ring attachment are integrally formed.

12. The motor of claim 9, wherein each block includes a positive integer number X of phases of coil windings, and wherein an angular position of largest flux magnitude for each winding is spaced apart from angular positions of largest flux magnitude of adjacent windings by an angle of π/NX radians.

13. (canceled)

14. The motor of claim 1, wherein each coil winding in each block comprises a repeated winding pattern such that each phase winding is wound in a first direction and consecutively wound in a second direction opposite to the first direction.

15. The motor of claim 1, wherein the N number of distinct blocks have an N-fold rotational symmetry about the rotational axis such that equivalent locations in each block are spaced apart by 2π/N radians.

16. The motor of claim 13, wherein each sensor included in the plurality of sensors is spaced apart from each other sensor by an angle in radians of: $n\left(\frac{2\pi }{N}\right)+m\left(\frac{2\pi }{N.Math.X}\right)$ wherein n is any integer and m is any integer except 0 or pX and in which p is any integer.

17. The motor of claim 13, wherein each sensor included in the plurality of sensors being spaced apart from each other sensor by an angle in radians of: $n\left(\frac{2\pi }{N}\right)+m\left(\frac{\pi }{N.Math.X}\right)$ wherein n is any integer and m is any integer except 0 or 2pX and in which p is any integer.

18. The rotor position sensing element of claim 7, wherein the sensor ring attachment is configured to couple to the gap between adjacent blocks, and wherein an end of the sensor ring attachment is configured to be held in the gap between adjacent blocks.

19. (canceled)

20. The rotor position sensing element of claim 7, comprising a plurality of sensor ring attachments each configured to couple to a different gap between adjacent blocks.

21. The rotor position sensing element of claim 7, wherein at least one of the plurality of sensors is held in a fixed position relative to the sensor ring attachment.

22. The motor according to claim 1, wherein the sensor ring attachment(s) is/are formed as a tapering projection, and wherein the tapering projection is shaped to match the shape of the gap.

23. (canceled)

Description

DRAWINGS

[0030] Embodiments of the disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0031] FIG. 1 shows a slotless motor with a rotor position sensing element assembly.

[0032] FIG. 2 shows an exploded view of an example of a slotless motor comprising a rotor position sensing element.

[0033] FIG. 3a shows exemplary individual coil windings wires forming a block of coil windings for a slotless motor.

[0034] FIG. 3b shows exemplary coil windings for a slotless motor.

[0035] FIG. 4a shows a perspective view of a sensor ring and sensor ring attachment coupled to a motor end cap.

[0036] FIG. 4b shows a front on view of a sensor ring and sensor ring attachments coupled to a motor end cap.

DETAILED DESCRIPTION

[0037] Embodiments of the claims relate to a slotless motor with a precise rotor positioning measuring system. In particular, embodiments of the claims relate to a rotor position sensing element comprising a sensor ring and a sensor ring attachment that holds the sensor ring fixed relative to the coil windings that may be used, for example, in a slotless motor comprising a stator comprising coil windings and a rotor comprising permanent magnets. As a result, the system can help to provide more precise motor control, thus increase the efficiency of the motor.

[0038] FIG. 1 shows a system 100 comprising a slotless motor 110 and rotor position sensing element assembly 111. The rotor position sensing element assembly comprises sensor connector 112 and connector plug 120 for connecting to a motor controller (not shown). The sensor connector 112 is configured to couple to the sensor ring in order to transfer the sensor signals to the motor controller via connector plug 120. This embodiment shows a wired connection between the sensor connector 112 and connector plug 120, however, it will be understood that the transfer of sensor data may be achieved through a wireless connection, for example, via Bluetooth™ or Wi-Fi™ where the sensor connector comprises a wireless module configured to communicate with a wireless module coupled to the sensor connector.

[0039] FIG. 2 shows an example of an exploded view of a slotless motor assembly 200 comprising a slotless motor 210 comprising a rotor position sensing element 217, 218, 219. FIG. 2 shows a slotless motor 210 comprising a heat sink motor housing 213, stator 205, a sensor ring attachment 217, sensor ring 219, sensor PCB 218 and motor housing end cap 201.

[0040] The stator 205 comprises a coil winding assembly 206 which has a plurality of coil windings arranged into distinct blocks 206a, 206b and further comprises a flux ring 208 that encompasses the coil winding assembly, all of which, in this example, is encompassed by a heat sink motor housing 213. Providing a heat sink on the motor housing aids in temperature regulation of the motor itself. It will also be appreciated that the addition of a flux ring increases the strength of the magnetic field generated when a current is passed through the coil windings.

[0041] Each of the distinct blocks 206a, 206b of the coil winding assembly 206 has a gap between the adjacent blocks 206a, 206b. The rotor 203 which is rotatable about a rotational axis P has permanent magnets 203a, 203b spaced about its circumference and is placed within the stator 205 and motor housing 213 such that it is completely encompassed by the stator 205. The rotational axis P extends through the centre of the entire motor assembly and in this example the plurality of distinct blocks 206a,206b are spaced about the axis P in an N-fold rotational symmetry where in N is the number of distinct blocks 206a,206b.

[0042] In this example, the sensor ring 219 together with sensor ring attachment 217 and sensor PCB 218 make up the rotor position sensing element 217, 218, 219. The sensor ring 219 comprises at least one sensor capable of sensing the magnetic field of the magnets 203a, 203b on the rotor 203. The sensor PCB 218 may provide basic circuitry to the sensor on the sensor ring 219 and provide a coupling point for the sensor connector 112. In some embodiments the sensor is any one of: a magnetic field sensor, for example a hall-effect based position sensor or a magnetostrictive position sensor, a potentiometric position sensor, an inductive position sensor, an eddy current-based position sensor, a capacitive position sensor, a fibre-optic position sensor, an optical position sensor and an ultrasonic position sensor. In some embodiments the sensor PCB 218 may be housed in the sensor connector 112 which is configured to couple to the sensor ring 219 and receive sensor readings. The sensor ring attachment 217 is configured to hold the rotor position sensor element 217, 218, 219 relative to at least one of the distinct blocks such that the sensor is maintained in a predetermined location relative to the stator 205 and coil winding assembly 206. The sensor ring attachment 217 may have a tapering projection which may be configured to fit in a gap between the adjacent blocks 206a,206b. The rotor position sensing element 217,218,219 is also coupled to motor end cap 201 such that the length of the motor is not increased by the addition of the rotor position sensing element. It will be appreciated that although three sensor ring attachments are shown, it is possible to hold the rotor position sensing element in a fixed position using one or a plurality of sensor ring attachments wherein each of the plurality of sensor ring attachments are configured to fit in a different gap between the adjacent blocks.

[0043] In normal functioning of the motor, a magnetic field will be generated in the stator which will cause the rotor to rotate about the rotational axis. The sensor on the sensor ring 219 measures the magnetic field produced by the magnets on the rotor 203. The characteristics of the magnetic field measurement provides detail on the current orientation of the rotor i.e. the polarity of the magnetic field, the field strength etc. Once the orientation of the rotor 203 is known it is possible to derive which phase and associated coils in the windings need to be energised to create a torque in the rotor 203 to cause it to rotate in the desired direction and at the desired speed. For example, in the case of a permanent magnet rotor, a permanent magnet on the rotor 203 having a north pole directed radially outward may generate a magnetic field in the region of the sensor, the magnetic field having a certain polarity, in this example north, and a strength dependent on the spacing between the magnet and the sensor and the strength of the magnet. This north pole may be the closest magnet to the sensor which may relay the information to a motor controller. Although the working example has been described in the context of a permanent magnet rotor, it would be understood by the skilled person that other versions of rotor may also be used with the use of an appropriate sensor.

[0044] As the orientation of the sensor ring 219 comprising the sensor is fixed relative to the stator 205, in this example via the coil winding assembly 206 and sensor ring attachments, the motor control system is able to determine the rotor 203 position and orientation relative to the stator. It can then provide current to energise the appropriate coil winding(s) 206 at the appropriate polarity in order to generate a torque in the rotor 203 to cause it to rotate.

[0045] FIG. 3a and FIG. 3b show an example of coil windings in a slotless motor. The individual coil wires 301a-301n are coupled together to form blocks of coil windings 302 around the rotational axis P of the motor forming the coil assembly with a first axial end and a second axial end. The way in which the blocks 302a, 302b, 303c are wound produces a gap between adjacent blocks at the first axial end 302a, 302b, 302c and second axial end 304a, 304b of the coil windings. In some embodiments the coil windings comprise a positive integer X phase wherein each block 306a, 306b, 306c comprises a different phase. In some embodiments each distinct block 306a, 306b, 306c may include a positive integer number X of phases of coil windings. In preferred embodiments each block 306a, 306b, 306c comprises three phases of coil windings. That is to say that each individual coil wire 301a-301n is configured to carry current at one of the phases. In some embodiments each individual coil wire is configured to carry current at a different phase to an adjacent coil wire. In either case the individual coils are wound in a first direction towards the first axial end 302 forming a block and then wound in a second direction towards the second axial end 304 forming a block. This allows each coil in the same phase to be in series.

[0046] As each coil wire becomes energised is a magnetic field is created and the angular position of largest flux magnitude for each winding is spaced apart from angular positions of largest flux magnitude of adjacent windings is given by an angle of π/NX radians, where N is the number of distinct blocks and X is the number of phases in a block. A sensor measurement at, or close to these points, would be indicative of the maximum torque that can be generated at a given rotor position and orientation. This is because the point of largest flux magnitude is the point that the magnetic field is at the strongest which will create the largest torque on the rotor, for example in the case of a permanent magnet rotor, to force the appropriate magnet pole in alignment with the generated magnetic field of the coils. This would also apply to a reluctance motor whereby the flux barriers on the rotor for a reluctance motor would force the rotor to be aligned with the magnetic field lines generated by the coils.

[0047] In the embodiment shown in FIG. 3a and FIG. 3b each block comprises a repeated winding pattern such that each phase winding is wound in a first direction and consecutively wound in a second direction opposite to the first direction. Each block would therefore have an X phase pattern in a first direction of induced magnetic field followed by an X phase pattern in a second direction of induced magnetic field opposite to the first i.e. (A.sub.↑, B.sub.↑, C.sub.↑, A.sub.↓, B.sub.↓, C.sub.↓), wherein the arrows represent the direction of the induced magnetic field. The N number of distinct blocks have an N-fold rotational symmetry about the rotational axis P such that equivalent locations in each block are spaced apart by 2π/N radians. In other words, each block has an identical configuration evenly spaced about the rotational axis such that, from any given starting point rotations of an angle calculated as any positive integer multiplied by 2π/N radians results in an equivalent coil location.

[0048] FIG. 4a and FIG. 4b show a perspective and frontal views of an example of a motor housing end cap 401 comprising a rotor position sensing element. In this example, the end cap 401 and sensor ring attachments 417a, 417b are integrally formed. the sensor ring 419 may comprise nodule 421 which is configured to couple to a hole of corresponding shape and size on the end cap such that the sensor ring 419 is coupled to the end cap in a predetermined manner. In some embodiments, the sensor ring attachments 417a, 417b and/or sensor ring 419 may be milled or casted with the motor end cap 401. In some embodiments, the sensor ring attachments 417a,417b and/or sensor ring 419 may be coupled to the motor end cap 401 via welding, gluing or some other means of fusing the two components together.

[0049] Because the rotor position sensing element 419,417 are couplable (or coupled) to the motor end cap 401 the rotor position sensing element may be held in a fixed position relative to the motor housing 213. The rotor position sensing element 417,419 can therefore be held fixed relative to the coil windings of the stator wherein the rotor position elements are tapered so as to fit in between the gap between two adjacent coil winding blocks 306a, 306b. In some embodiments the shape of the sensor ring attachments 417a, 417b are designed to fit between the gaps between adjacent coil winding blocks 306a, 306b. By holding the rotor position element 417,419 fixed relative to the stator the sensors can be placed at predetermined locations relative to a particular phase of a coil winding or block of coil windings. The rotor position readings provided to the motor controller thereby show the position of the rotor relative to the stator.

[0050] In other words, the rotor position sensor element is held relative to at least one, and in some cases all of the coil windings of the stator, the axis of rotation of the rotor and the motor casing in general. Advantageously, any measurements made by the rotor position sensing elements may be completed with an increased level of precision and accuracy as the readings have reduced interference from dimension tolerances of the components of the motor assembly components.

[0051] In the context of the present disclosure other examples and variations of the systems described herein will be apparent to a person of skill in the art. It will be appreciated from the discussion above that the embodiments shown in the Figures are merely exemplary, and include features which may be generalised, removed or replaced as described herein and as set out in the claims.