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楼主: modisc
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电机绕线贴(Rcgroups/modisc)

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421
 楼主| 发表于 2012-7-26 17:32 | 只看该作者

IPM

东西研究的深入了,越来越多的新东西就冒出来了,这是一个很令人享受的过程。
这几天在rcgroups上的讨论让我受益匪浅,原贴:http://www.rcgroups.com/forums/showthread.php?t=1695789

里面有些参考文献,关于磁铁内置转子(Iternal permanent magnet, IPM)和磁铁外置转子(Surface permanent magnet, SPM)。总之IPM是一种比较流行的设计,具有转子机械强度高,成本低等优势,在应用和具体参数方面和SPM各有千秋,等有时间再好好读一下那些参考文献

http://endless-sphere.com/forums ... =30&t=41153#p601972

http://eprints.whiterose.ac.uk/869/1/zhuzq11.pdf
This is a paper discussing the cogging, but there is a sentence in the introduction:
However, machines equipped with in- terior-magnet rotors generally have a higher torque density due to the saliency torque component and require less permanent magnet material. They also exhibit a higher demagnetization withstand capability, which is an important consideration under flux-weakening operation.

http://jap.aip.org/resource/1/japiau/v93/i10/p8769_s1
This is a paper discussing how to improve IPM motor. But in the abstract, there is again, a sentence might be useful:
The most significant benefit of the IPM rotor is its mechanical reliability, because permanent magnets are inserted in slots of soft magnetic material. On the other hand, there is significant leakage flux between adjoining permanent magnets in the soft magnetic rotor core, reducing the usable magnetic flux flowing into the stator core.

http://www.faqs.org/patents/app/20080224558#b
This is a very long and detailed description of a patent related to IPM. I can't read all, but it seems IPM is good. Hope someone who specialized in this area can summarize some useful points from this research.

http://eprints.whiterose.ac.uk/872/1/zhuzq14.pdf
Conclution of this paper:
The stator iron loss in brushless ac motors, having a surface- mounted magnet rotor and an interior-mounted magnet rotor, respectively, has been investigated under both constant torque and constant power operating modes. Whilst the interior-magnet motor facilitates extended flux-weakening operation, its iron loss can be significantly higher in the flux-weakening operating range.

http://www.aosmith.com/WorkArea/Down...et.aspx?id=474
Finally, here comes something conclusive and covering all aspects of IPM:
On the other hand, IPM motors typically employ less expensive rectangular blocks, which are placed inside slots made in the laminated rotor core. Magnet retention is therefore enhanced and yields to simplifications in the manufacturing process.
Another major type of IPM rotor (not shown) employs magnets placed in a “spoke” arrangement along the rotor radius and magnetized tangentially. The “spoke” design has the intrinsic advantage of magnetic flux concentration, so that in high polarity motors the flux density in the motor air-gap is increased. This leads the way to further performance improvement and/or size reduction. Many combinations of the magnet shape, position and number of magnets per pole is possible for IPM motors. In recent years, A. O. Smith Corporation has developed proprietary solutions to optimize designs for different applications.
magnetic field of the air-gap, in an IPM the PMs are shielded by the rotor steel that provides a leakage path for the arma- ture reaction flux. As a consequence, thinner magnets can be employed, potentially resulting in material cost savings.
The synchronous electromagnetic torque in an IPM motor has two major components (Fig. 2). The main component is the alignment torque, which is proportional with the flux linkage in the stator windings produced by the rotor magnets and with the vector component of the stator current that is in quadra- ture with the magnet flux. This current component is “active” only, i.e. only produces torque and does not contribute to the magnetization of the motor magnetic circuit. In an SPM, this is the only synchronous component of the electromagnetic torque.
In an IPM, due to the rotor variable magnetic reluctance, i.e. saliency, an additional torque component is developed. By means of electronic control, the torque angle, i.e. the angle between the magnet flux phasor and the current phasor, can be optimally set in order to increase the torque output for a given current magnitude. In the example of Fig. 2 the optimal angle is approximately 115 degrees.
Fig. 2 Electromagnetic torque components in an example IPM motor. Drive electronics tracks rotor position and controls the vector current in order to maximize torque production.
This maximum torque per amp control procedure requires a demagnetizing current component that also reduces the mag- netic circuit loading and core losses. As shown in the graph, an IPM motor has the potential of increased specific power or reduced size for the same rated power, as compared with an SPM machine. At reduced loads, both the active (quadra- ture) and demagnetizing current component are reduced yielding a relatively flat efficiency curve, yet another advantage of BLPM machines over induction motors.

http://ieeexplore.ieee.org/ielx5/41/...number=5352216
An Interesting IPM rotor design, with magnets places radially in the iron lamination core.

http://ieeexplore.ieee.org/ielx5/523...number=5259072
A direct comparison between IPM and SPM, though this IPM rotor design is a different. Seems IPM is more favorable.


[ 本帖最后由 modisc 于 2012-7-26 17:42 编辑 ]

欢迎继续阅读楼主其他信息

422
发表于 2012-7-27 10:16 | 只看该作者
:em23:不懂。翻译的看不懂
423
发表于 2012-7-27 13:51 | 只看该作者
技术贴,收藏慢慢学习
424
发表于 2012-7-31 18:17 | 只看该作者
:em24:
425
发表于 2012-8-2 07:57 | 只看该作者
:em26:
426
发表于 2012-8-2 16:30 | 只看该作者
高人啊!!必须收了~~哈哈
427
发表于 2012-8-2 23:00 | 只看该作者
都是师傅啊!要好好学一下
428
发表于 2012-8-10 06:58 | 只看该作者
好贴,正需要,帮顶,向楼主致敬:em00:
429
 楼主| 发表于 2012-8-10 12:14 | 只看该作者
来自henrym3的汽车水泵电机改造:原帖地址:http://www.rcgroups.com/forums/showthread.php?t=1702483#post22405862

基本数据:

stator outer diameter: 78.2mm
stator inner diameter: 39.8mm
stator lamination thickness: 0.35mm
stator height: 30mm
rotor height: 37mm, inner magnets height: seems to be 30mm
rotor diameter: 35.8mm
rotor structure: internal permenant magnets (IPM), 2 pieces, to form a NSNS 4-pole rotor (as shown in the attached pics)
orginal "bearing": carbon tube
original windings: 28 turns of 0.9mm wire each tooth (56T)
original driving board: unknown driving board, directed glued on the motor back
original Kv: unknown, since the winding is not clear to me, seems to be a 6N4P ABCABC, DD connection.


winding: single strand 2.24mm wire, 21T, Y
Kv: 580 rpm/v
Rm: 0.0455 ohm
Io: 1.25A@11.8V, 2.04A@23.0V
Best efficiency current based on Rm and Io: 18A@11.8V, 32A@23V
Overall weight including ESC: 1800 gram

目前用该电机带动一个自己拼的15X10的4叶桨(两个劲旋风15X10,四个叶片末端裁去了约2.5mm),11.2V,18A。

首先必须感谢henrym3提供的电机,和亲手为我打造的一把极品绕线工具,没有这把工具,我是无法完成2.24mm这么粗的线的绕线的。可谓艺术品。


该电机扭矩惊人,用手感觉比我目前最大的6374的外转子还要大(5340定子尺寸,180Kv)。由于定子和转子特殊设计,该电机基本没有顿感,因此11.8V下,1/20油门便可开始缓慢平滑转动,1/10油门下,转速虽然很低,可能只有每分钟100转以内,但已基本用手(或戴皮手套)捻不住转轴,力量很大。
目前一个比较大的问题就是电机有不寻常的振动和噪音,经过测试初步判断可能是轴承的问题,希望换了EZO轴承后能解决。


总体来说,至此安装电机、测试结果均十分理想。下面是一系列图了。

An interesting calculation:
As i mentioned before, the original winding is 58T, connection type seems to be DD.
As a reference, the speed of engine cooling water pump is around 6000 -9000 rpm.
So: For my Y connection, winding constant (Yc) = Kv X number of turns = 580 X 21 = 12180
converting the Yc to DDc: DDc = Yc X 2 X 1.732 = 42192
So the original Kv is DDc/ original number of turns = 42192/58 = 727.45
Assuming the working voltage of the original pump is 12V : then the working speed is 12 X 727.45 = 8729. which is well in the range of 6000-9000.

[ 本帖最后由 modisc 于 2012-8-10 13:50 编辑 ]

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430
发表于 2012-8-10 12:44 | 只看该作者
:em19:
431
发表于 2012-8-10 12:47 | 只看该作者
电机真给力。。。。:em15:
432
发表于 2012-8-11 14:28 | 只看该作者
好像很复杂的样子
433
 楼主| 发表于 2012-8-13 01:59 | 只看该作者
终于完成了。

原帖地址:http://www.rcgroups.com/forums/showpost.php?p=22425238&postcount=12

整个里面塞了个200A 6S的电调,Turbojet的便宜货,引出来的两个插口,一个插舵机测试仪,一个直接插电源(手头没高级插头,就普通T插了)。

电机Kv598, 21T Y。帮henrym3最后绕的一个定子实现了11+11T,22T,以后有时间我自己再重新绕一下了。22T Y的话,Kv应该是571。

轴承用的是EZO的10*19*5,还是有点点震动感,但是总算是和谐的振动了,强度也比之前弱多了。估计造成振动的原因在于普通钢球轴承受到比较强的轴上的磁力影响。如果换陶瓷球轴承或许能实现完美静音。

电机基本没有顿感,归功于转子和定子的形状和设计。

另外,电机发热情况十分理想。23.8V空载电流2A多点点(2.05?),持续空转3分钟,内部定子温度仅38度,室温26度,转子温度更低一些。普通一个4130的600kv的电机6S空转3分钟基本上要烫手了。

整个一大坨电机/内置电调,1.8Kg,保留了原有的放水设计。如果以后实际应用需要额外散热,还可以打孔。

总体来说算是很骚的一个动力组合,上天是不太可能了,Kv太高。。。不过作为12-14S的1/4或1/5的车模动力,应该还是很有希望的。







434
发表于 2012-8-13 08:44 | 只看该作者
这电机用来改CNC主轴貌似不错 ,6S  10000多转
435
 楼主| 发表于 2012-8-13 13:40 | 只看该作者
原帖由 6eyesdog 于 2012/8/13 08:44 发表
这电机用来改CNC主轴貌似不错 ,6S  10000多转

目前电机存在两大问题:

一个就是振动。理论上来说,该电机基本每顿感,而且是德国制造,汽车水泵工作转速也在6000-9000rpm,相信转子应该动平衡比较好;那么这个电机转动起来应该是不会有任何振动的。但是目前还是有振动,确实怀疑是轴上的强磁力影响钢球轴承所致。有没有高人有过类似经验?

另一个就是电调,说过了是便宜货,低油门的时候会有点点不协调,油门大于50%就基本线性调速了。
436
发表于 2012-8-13 14:37 | 只看该作者

给力

我把电机壳子改造了一下
437
发表于 2012-8-13 14:39 | 只看该作者
原帖由 henrym3 于 2012-8-13 14:37 发表
我把电机壳子改造了一下

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438
发表于 2012-8-13 14:40 | 只看该作者
原帖由 henrym3 于 2012-8-13 14:39 发表

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439
 楼主| 发表于 2012-8-13 17:02 | 只看该作者
原帖由 henrym3 于 2012/8/13 14:39 发表
你看对称的三根柱子,都被你磨掉了,那三个柱子也是为了加强这么薄壁的外壳。

看着很骚,但太不结实了。要是不磨掉前盖就好了。
440
发表于 2012-8-14 09:45 | 只看该作者
:em15: :em15:
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