This paper deals with the effects of welding, which is done to fix the stator stack, on a motor in case of fabricating a prototype motor that is manufactured in a small quantity. In the case of a small motor, the stator is designed and fabricated with the segmented core as a way to raise the fill fa...
This paper deals with the effects of welding, which is done to fix the stator stack, on a motor in case of fabricating a prototype motor that is manufactured in a small quantity. In the case of a small motor, the stator is designed and fabricated with the segmented core as a way to raise the fill factor of winding wire to the utmost within a limited size. In case of fabrication by welding both inside and outside of the stator in order to fix the segmented-core stator, the effects of stack are ignored, and the eddy current loss occurs. This paper performed the no-load test on an IPM-type BLDC motor for driving the suction fan of a vacuum cleaner, which was manufactured by using a segmented-core stator. As a result of the test, it was found that input power more than expected was supplied. To analyze the effects of welding by using the finite element analysis method and verify them experimentally, a stator was re-manufactured by bonding, and input power supplied during the no-load test was compared.
This paper deals with the effects of welding, which is done to fix the stator stack, on a motor in case of fabricating a prototype motor that is manufactured in a small quantity. In the case of a small motor, the stator is designed and fabricated with the segmented core as a way to raise the fill factor of winding wire to the utmost within a limited size. In case of fabrication by welding both inside and outside of the stator in order to fix the segmented-core stator, the effects of stack are ignored, and the eddy current loss occurs. This paper performed the no-load test on an IPM-type BLDC motor for driving the suction fan of a vacuum cleaner, which was manufactured by using a segmented-core stator. As a result of the test, it was found that input power more than expected was supplied. To analyze the effects of welding by using the finite element analysis method and verify them experimentally, a stator was re-manufactured by bonding, and input power supplied during the no-load test was compared.
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제안 방법
1 shows the structure of the fabricated primary prototype motor and the results of no-load test. And Section 3.2 analyzed the problem of stator welding, using the finite element analysis method; and fabricated the secondary prototype motor by bonding, not welding, for the verification of experiment, and performed a no-load test in the same way as in the primary prototype. The results of no-load tests on the primary prototype and the secondary prototype were compared; and the effects of stator welding on the motor were verified.
As for the method of simulation, a 3D model was designed so that the effects of welding might be observed in a simplified way.
To verify this by experiment, a secondary prototype was fabricated by using the bonding method, not welding the stator. The no-load test was performed with the primary prototype and the secondary prototype under the same environment, and the results of FEM analyses were comparatively verified by comparing electric energy inputted in the BLDC motor at each driving speed.
Therefore, the waveform of back electromotive force becomes sinusoidal irrespective of the magnetization direction of a permanent magnet. Then, it was confirmed that a torque value satisfying the required torque came out in the simulation under no-load condition, and the motor efficiency was calculated using air-gap power, core loss, permanent magnet loss, and copper loss.
The 2D analysis with a small number of finite elements can be used for a basic design that meets the requirements of the motor within a limited size, but fails to consider the structure of overhang to detect the position of the rotator and the effects of winding wire end-turn. Therefore, as shown in Fig. 3, the 3D model was modeled on the basis of a 2D basic model, and analysis was performed in consideration of the structure of rotator overhang and the end-turn effects of stator winding wire[8, 9].
The vacuum cleaner of this study works most with a suction orifice diameter of Φ 11. Therefore, the load at this time was calculated as the rated load, and the design was developed by focusing on the efficiency of the motor unit and the efficiency of the system, which includes the inverter and the fan, at the rated load. As for the capacity, DC voltage of 36 [V] (ten 3.
This chapter introduces general matters on calculating and designing the load of a high-speed BLDC motor for driving the suction fan. Section 2.
This paper verified the problem, which may arise in the design of 500 [W] BLDC motor for driving a suction fan and in the prototype motor manufactured in a small quantity, by FEM analysis and experiments with fabrication models.
This study verifies and proposes from the FEM analysis and the results of experiment that in case of fabricating a motor, the welding zone should be selected lest a magnetic closed-loop be formed.
Therefore, the effects of welding were identified by 3D FEM analysis in terms of whether current density caused by welding occurred or not. This was not a problem because this study aimed to investigate the effects of welding, and the analysis was performed with a simplified model setting the rotator speed to 80,000 [rpm].
대상 데이터
In the design flow, magnetic loading and electric loading were properly used to minimize the size, and materials were also selected so that they might be able to meet the driving temperature and the required output power. For the permanent magnet, N38UH of Nd series was used; and for the core, the material of 20PN1500 (based on POSCO company) with the thickness of 0.2 [T] was used.
The prototype motor developed from R&D of this paper is an interior permanent magnet-type (hereinafter, "IPM") brushless direct current (hereinafter, "BLDC") motor designed to drive the load of a suction fan for a vacuum cleaner.
As a result of designing smaller slot openings so as to reduce output ripple, it was inevitable to manufacture the prototype with the segmental cores of the stator. Thus, the prototype was manufactured with six segmental cores, the same number as the number of slots. In addition, as for the welded zone, a total of 30 areas including 12 internal areas of the stator and 18 external areas of the stator were welded.
이론/모형
In the case of this motor, however, it is intended to raise the stability of control during high-speed driving by detecting more correctly the location of a rotator for BLDC control. lengthened by overhang, 2D analysis and 3D analysis were carried out together, using the finite element analysis method. The 2D analysis with a small number of finite elements can be used for a basic design that meets the requirements of the motor within a limited size, but fails to consider the structure of overhang to detect the position of the rotator and the effects of winding wire end-turn.
성능/효과
2 analyzed the problem of stator welding, using the finite element analysis method; and fabricated the secondary prototype motor by bonding, not welding, for the verification of experiment, and performed a no-load test in the same way as in the primary prototype. The results of no-load tests on the primary prototype and the secondary prototype were compared; and the effects of stator welding on the motor were verified.
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