Electronically commutated motor
First Claim
1. A DC motor comprising a stationary armature having a core and at least two winding stages each comprising at least one effective winding;
- each winding comprising at least two coils of winding turns accommodated by the core and arranged to establish a predetermined number of magnetic poles, and the winding turns of each winding having a number of sets of axially extending conductor portions with such member being equal in number to the predetermined number of poles;
the axially extending conductor portions within each given set being comprised generally of about one half of the conductor side turn portions of at least two different coils, and such conductors being disposed to conduct current instantaneously in the same axial direction along the core thereby contributing to the establishment of magnetic poles when the winding containing such given set is energized;
the arcuate spread of any given set of axially extending conductors being less than about 120 electrical degrees;
a rotor having constant magnetic polarity polar regions equal in number to the predetermined number of poles, said rotor being adapted to rotate relative to the armature in response to the magnetic poles established by the winding turns; and
commutation means for energizing the windings in a predetermined manner to establish the magnetic poles on said armature for causing rotational movement of the rotor.
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Accused Products
Abstract
A brushless DC motor is constructed with photosensitive device for detecting rotor shaft position. Arcuate permanent magnets on the rotor provide a DC flux field while distributed stationary armature windings, each spanning a fixed number of slots in the armature assembly, provide mutually perpendicular magnetic fields. A logic circuit comprising NOR gates and transistor switches and drivers activated in response to signals from the shaft position sensors are utilized to control current switching in the armature windings of the motor. A light interrupting shutter mounted to the rotor cooperates with the light sensitive devices which are mounted to a supporting bracket fixed to the stationary armature assembly in a manner to selectively preset advancement of commutation of the armature windings. Variations on permanent magnet rotor construction and novel applications of a brushless DC motor are also disclosed as is a novel approach for dispensing with the mechanism for detecting the shaft position. In this last respect a commutating circuit is disclosed for a brushless DC motor, including a detecting circuit responsive to the electromotive force (emf) of the brushless DC motor to provide a simulated signal indicative of the rotation of the motor'"'"'s shaft and a logic circuit responds to the output of the shaft position detecting circuit to control the application of driving signals through the armature windings of the DC brushless motor.
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Citations
44 Claims
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1. A DC motor comprising a stationary armature having a core and at least two winding stages each comprising at least one effective winding;
- each winding comprising at least two coils of winding turns accommodated by the core and arranged to establish a predetermined number of magnetic poles, and the winding turns of each winding having a number of sets of axially extending conductor portions with such member being equal in number to the predetermined number of poles;
the axially extending conductor portions within each given set being comprised generally of about one half of the conductor side turn portions of at least two different coils, and such conductors being disposed to conduct current instantaneously in the same axial direction along the core thereby contributing to the establishment of magnetic poles when the winding containing such given set is energized;
the arcuate spread of any given set of axially extending conductors being less than about 120 electrical degrees;
a rotor having constant magnetic polarity polar regions equal in number to the predetermined number of poles, said rotor being adapted to rotate relative to the armature in response to the magnetic poles established by the winding turns; and
commutation means for energizing the windings in a predetermined manner to establish the magnetic poles on said armature for causing rotational movement of the rotor. - View Dependent Claims (2, 3, 4, 5, 6, 7)
- each winding comprising at least two coils of winding turns accommodated by the core and arranged to establish a predetermined number of magnetic poles, and the winding turns of each winding having a number of sets of axially extending conductor portions with such member being equal in number to the predetermined number of poles;
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8. A DC motor comprising a stationary armature having a core and at least two winding stages each comprising at least one effective winding;
- each winding comprising concentric winding turns accommodated by said core and arranged to establish a predetermined number of magnetic poles and the winding turns of each winding having a number of sets of axially extending conductor portions with such number equal to the predetermined number of magnetic poles;
the axially extending conductor portions within each set being disposed in said armature to conduct current instantaneously in the same axial direction along the core thereby contributing to the establishment of magnetic poles when the winding containing the given set is energized;
the arcuate spread of any given set of axially extending conductors being less than about 120 electrical degrees;
a rotor having constant magnetic polar regions equal in number to the predetermined number of poles, said rotor being adapted to rotate in response to the magnetic poles established by the winding turns; and
a commutation circuit for energizing the windings in a predetermined manner wherein said commutation circuit includes a detector circuit for sensing a back emf signal indicative of the back emf condition of at least one winding, position determining circuit means for conditioning the back emf signal sensed by the detector circuit and for producing a simulated relative position output that is indicative of the relative angular position of the rotor and armature, with such relative position output determined by the back emf condition of a winding, and circuit means interconnected with the position determining circuit means for supplying an output signal for energizing a selected one of the windings. - View Dependent Claims (9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22)
- each winding comprising concentric winding turns accommodated by said core and arranged to establish a predetermined number of magnetic poles and the winding turns of each winding having a number of sets of axially extending conductor portions with such number equal to the predetermined number of magnetic poles;
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23. A DC motor comprising a stationary armature having a slotted core and at least two winding stages each comprising at least one effective winding;
- each winding comprising at least one coil of winding turns accommodated in nonadjacent slots disposed around a bore of the core and arranged to establish a predetermined number of magnetic poles, and the winding turns of each winding having a number of sets of axially extending conductor portions with such number being equal in number to the predetermined number of poles;
the axially extending conductor portions within each given set being comprised generally of one half of the conductor portions of the at least one coil, and such conductors being disposed to conduct current instantaneously in the same axial direction along the core thereby contributing to the establishment of magnetic poles when the winding containing such given set is energized;
the arcuate spread of any given set of axially extending conductors being less than 120 electrical degrees;
a rotor having constant magentic polarity polar regions equal in number to the predetermined number of poles, said rotor being adapted to rotate relative to the armature in response to the magnetic poles established by the winding turns; and
commutation means for energizing the windings in a predetermined manner to establish the magnetic poles on said armature for causing rotational movement of the rotor.
- each winding comprising at least one coil of winding turns accommodated in nonadjacent slots disposed around a bore of the core and arranged to establish a predetermined number of magnetic poles, and the winding turns of each winding having a number of sets of axially extending conductor portions with such number being equal in number to the predetermined number of poles;
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24. A DC motor comprising a stationary armature having a core and at least two winding stages each comprising at least one effective winding;
- each winding comprising concentric winding turns accommodated by the core and arranged to establish a predetermined number of magnetic poles, and the winding turns of each winding having a number of sets of axially extending conductor portions with such number being equl in number to the predetermined number of poles;
the side turn axially extending conductor portions within each given set being disposed to conduct current instantaneously in the same axial direction along the core thereby establishing a predetermined spread and contributing to the establishment of magnetic poles when the winding containing each given set is energized;
a rotor having a plurality of permanent magnet segments disposed thereon and adapted to rotate in response to the magnetic poles established by the armature;
a commutation circuit for energizing the windings in a predetermined manner and at a predetermined angle of advance α
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wherein each permanent magnet segment establishes a constant magnetic polar region about said rotor which is about equal in electrical degrees to the winding spread plus 180 (N-1)/N minus 2 α
where N equals the number of winding stages of the motor. - View Dependent Claims (25, 26, 27)
- each winding comprising concentric winding turns accommodated by the core and arranged to establish a predetermined number of magnetic poles, and the winding turns of each winding having a number of sets of axially extending conductor portions with such number being equl in number to the predetermined number of poles;
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28. A DC motor comprising a stationary armature comprising a core having a longitudinal axis and at least two different energizable windings each including concentrically disposed winding turns, the windings supported on said core to produce at least two spaced apart magnetic poles, a rotor having a predetermined number of constant polarity magnetic regions adapted to rotate about said longitudinal axis in response to magnetic fields established by said armature, commutation means for energizing said armature windings in a predetermined manner, at least two groups of winding turns each having a predetermined span of at least about 180 electrical degrees and wherein conductive turn segments in adjacent slots of the core arranged to carry current in the same relative axial direction have a predetermined spread less than 120 electrical degrees.
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29. A brushless DC motor comprising a stationary armature having a core and at least two winding stages each comprising at least one effective winding, each winding comprising concentric winding turns accommodated by the core and arranged to produce a predetermined number of magnetic poles, a rotor adapted to rotate about said longitudinal axis in response to the magnetic poles established by said armature, and a commutation circuit for energizing the windings in a predetermined manner wherein said commutation circuit includes a detector circuit comprising:
- means responsive to the current drawn by the armature windings to provide an output signal indicative thereof, means for scaling the output signal by a factor corresponding to the resistance of the armature windings, means for substracting the resulting scaled signal from the voltage applied to the armature windings to provide a signal indicative of the back emf of the brushless DC motor, and wherein the commutation circuit further includes a frequency circuit means responsive to the back emf signal for generating a signal of a frequency proportional thereto indicative of the rotor speed and with said frequency circuit means having a minimum frequency output signal to aid starting of the brushless DC motor.
- View Dependent Claims (30, 31, 32)
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33. A commutation circuit for a brushless DC motor having a stationary armature with a longitudinal axis, a plurality of windings disposed on said armature to produce magnetic fields, a rotor adapted to rotate about said longitudinal axis in response to the magnetic fields established by the armature, said commutation circuit comprising:
- a detector circuit for sensing the current drawn through the armature windings and for scaling the sensed current signal in accordance with the resistance of the windings, for sensing voltage applied to the winding, and for generating an output signal indicative of rotor speed;
an indexing means responsive to the detector circuit output signal for generating a plurality of output signals indicative of a relative position of said rotor with respect to said armature;
an energizing circuit means responsive to said plurality of output signals from said indexing means for energizing said windings in a predetermined sequence in accordance with the relative position of said rotor. - View Dependent Claims (34)
- a detector circuit for sensing the current drawn through the armature windings and for scaling the sensed current signal in accordance with the resistance of the windings, for sensing voltage applied to the winding, and for generating an output signal indicative of rotor speed;
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35. A brushless DC motor having a stationary armature with at least two different energizable windings disposed thereon for producing spaced apart magnetic fields and a rotor adapted to rotate about a longitudinal axis in response to the magnetic fields, said motor further comprising:
- a rotor position sensor for producing pulse output signals indicative of rotor position relative the stationary armature;
stepping logic circuitry responsive to the pulse output signals from the rotor position sensor for inhibiting continuous winding commutation in a predetermined sequence;
mode control circuitry responsive to the pulse output signals from the rotor position sensor, to rotational direction command signals, and to continuous and stepping operational command signals for producing an output for use in selecting a winding for energization;
a pulse modulating circuit responsive to the mode control circuitry for supplying an output signal for energizing a selected one of the windings; and
a current sensor responsive to the current flow through the windings of the motor for producing an output signal to said pulse modulating circuit for inhibiting the modulating circuit output signal for a predetermined period of time when the motor current exceeds a predetermined value so as to limit the magnitude of current supplied to the motor windings. - View Dependent Claims (36)
- a rotor position sensor for producing pulse output signals indicative of rotor position relative the stationary armature;
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37. A brushless DC motor having a stationary armature with at least two different energizable windings for producing spaced apart magnetic fields in time sequence, a rotor adapted to rotate about a longitudinal axis in response to the magnetic fields, and a commutation circuit for controlling commutation of the windings wherein said commutation circuit comprises:
- a position circuit for simulating rotor position in accordance with the back emf condition of at least one winding;
a circuit for energizing a selected one of the windings in accordance with the simulated rotor position; and
an under speed protection circuit operable to prevent the circuit for energizing a selected one of the windings from energizing any of the windings when the motor speed is less than a predetermined minimum value for a predetermined length of time. - View Dependent Claims (38, 39)
- a position circuit for simulating rotor position in accordance with the back emf condition of at least one winding;
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40. A brushless DC motor having a stationary armature with at least two different energizable windings disposed on said armature and energizable from a voltage source for producing spaced apart magnetic fields in time sequence, a rotor adapted to rotate about a longitudinal axis in response to the magnetic fields and a commutation circuit for controlling commutation of the windings wherein said commutation circuit comprises:
- a position circuit for simulating rotor position in accordance with the back emf condition of at least one winding;
a circuit for energizing a selected one of the windings with power from the voltage source in accordance with the simulated rotor position; and
an undervoltage protection circuit operable to prevent the circuit for energizing a selected one of the windings from energizing any of the windings when the voltage source output is less than a predetermined minimum value.
- a position circuit for simulating rotor position in accordance with the back emf condition of at least one winding;
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41. A brushless DC motor having a stationary armature with at least two different energizable windings disposed on said armature and energizable from a voltage source for producing spaced apart magnetic fields in time sequence, a rotor adapted to rotate about a longitudinal axis in response to the magnetic fields and a commutation circuit for controlling commutation of the windings wherein said commutation circuit comprises:
- a position circuit for simulating rotor position in accordance with the back emf condition of at least one winding;
a circuit for energizing a selected one of the windings with power from the voltage source in accordance with the simulated rotor position; and
an overvoltage circuit operable to prevent the circuit for energizing a selected one of the windings from energizing any of the windings when the voltage source output is greater than a predetermined maximum value.
- a position circuit for simulating rotor position in accordance with the back emf condition of at least one winding;
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42. A commutation circuit for a brushless DC motor having a stationary armature with at least two energizable windings disposed on said armature for producing spaced apart magnetic fields in time sequence, a rotor adapted to rotate about a longitudinal axis in response to the magnetic fields established by the armature and a commutation circuit for controlling commutation of the windings at a predetermined angle of advancement and wherein said commutation circuit includes means for aiding starting of the motor by generating a characteristic signal that is associated with an emf condition of the motor at low motor speed and wherein the characteristic signal is substantially less in magnitude than emf associated with the motor at full operating speed.
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43. A DC motor comprising a stationary armature having a core and at least two winding stages each comprising at least one effective winding;
- each winding comprising concentric winding turns accommodated by said core and arranged to establish a predetermined number of magnetic poles and the winding turns of each winding having a number of sets of axially extending conductor portions with such number equal to the predetermined number of magnetic poles;
the axially extending conductor portions within each set being disposed in said armature to conduct current instantaneously in the same axial direction along the core thereby to establish a magnetic pole when the winding containing the given set is energized;
a rotor having constant magnetic polar regions equal in number to the predetermined number of poles, said rotor being adapted to rotate in response to the magnetic poles established by the winding turns; and
a commutation circuit for energizing the windings in a predetermined manner wherein said commutation circuit includes a detector circuit for sensing a back emf signal indicative of the back emf condition of at least one winding, position determining circuit means responsive to only a positive polarity portion of the emf signal from the detector circuit for integrating said positive polarity portion of the emf signal to a predetermined value of a volt-seconds whereupon the position determining circuit means produces a simulated relative position output for establishing a predetermined advancement of commutation angle alpha of from about 5 electrical degrees to about 30 electrical degrees, and a circuit means responsive to the simulated relative position output from the position determining circuit means for supplying an output signal for energizing a selected one of the windings.
- each winding comprising concentric winding turns accommodated by said core and arranged to establish a predetermined number of magnetic poles and the winding turns of each winding having a number of sets of axially extending conductor portions with such number equal to the predetermined number of magnetic poles;
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44. A DC motor comprising a stationary armature comprising a core having a longitudinal axis and at least two windings disposed on said core to produce differently directed magnetic fields, a rotor adapted to rotate about said longitudinal axis in response to magnetic fields established by said armature, means for providing signals indicative of the relative rotational position of said rotor, and circuit means responsive to said signals for energizing said stator windings in a predetermined sequence, said means for providing being operative to cause advancement of commutation of the windings by an angle alpha of from about five to about twenty-five electrical degrees to aid the build-up of current when the windings are energized during running condition, wherein said means for providing signals indicative of the relative rotational position of said rotor includes a detector circuit for sensing a back emf signal indicative of the back emf condition of at least one winding and a means responsive to the back emf signal from the detector circuit for integrating the emf signal to a predetermined value of volt-seconds and for producing said signal indicative of the relative rotational position of the rotor.
Specification