Technical Field

The invention relates to a brushless electric motor with a hybrid rotor and stator topology.

Prior Art

Nowadays, brushless electric DC motors are being used in various structures. These motors are basically divided into ones with inner-rotor, outer-rotor, and axial-rotor structures. Each engine has its advantages and disadvantages, as well as different areas of use.

In the brushless DC motor with an inner rotor, the stator unit with electro-magnets is located in the outer part, and the rotor unit that provides the rotation is located in the inner part of the stator. This type of motor is more suitable for high-speed systems. The main disadvantage of this type of motor is the use of high-performance magnets to achieve a high magnetic flux density by using small permanent magnets in the rotor.

In an outer-rotor brushless DC motor, the electro-magnets are designed to be on the inside and the rotor unit on the outside. Since the rotor diameter is larger in this motor type, more magnets can be attached than in the inner rotor type, which increases the number of magnetic poles compared to the inner rotor type. But compared with the internal rotor type, the rotating shaft of the external rotor type motor has a more significant moment of inertia. This, in turn, makes it difficult for the rotor to start and stop faster.

The axial rotor is structurally disc-shaped and differs from the other two motor structures. In this type of motor, the magnetic flux is formed axially. This type of motor is generally preferred for low-power constant speed systems.

As a result of technical research, the abstract of the application with the number 2017/17512 is: "The present invention is related to a brushless DC motor, and the brushless DC motor developed with the invention provides more power and efficiency with the same DC current thanks to a second permanent magnet placed on the second poles of the coils." As can be seen, the said system relates to a brushless DC motor and does not mention a structure that can provide solutions to the disadvantages mentioned above.

As a result, an improvement in the technical field has been required due to the drawbacks mentioned above and the inadequacies of the existing solutions.

The Purpose of Invention

The invention is intended to provide a structure with different technical features, which, unlike the structures used in the present technique, brings a new development to this area.

The primary purpose of the invention is to provide the rotational action of the motor with the hybrid rotor and stator topology, with the magnetic force applied to the inner rotor, middle rotor, outer rotor, and axial rotor where the permanent magnet is located.

In the topology of the invention, the stator structure is designed to be an inner and an outer stator in the same way. The magnetic force to be applied to the permanent magnets is increased by placing the stators between the two rotors. Here, the N and S magnetic fields at the two opposite poles formed by the stators placed between the rotors are also utilized. This way, it will be ensured that the pull and repulsion magnetic field power generated in the stator is transferred to the rotors in a maximum way. In order to benefit more from the magnetic field strength, the number of rotors with the stator windings placed between the inner and outer rotors allows for a design of different strengths and speeds by increasing their number if necessary. In addition, to benefit from the axial flux created by the electro-magnet, permanent magnets will be added to the outer rotor holder, and the magnetic strength will be utilized to the maximum.

With the proposed topology, the advantages of all rotor structures are integrated into a standard structure by making more use of the magnetic power of the electro-magnet, and a more compact, high-speed, and high-power motor structure is revealed.

In order to fulfill the above-described objectives, the invention is a brushless electric motor with a hybrid rotor and stator topology, wherein; comprises,

An inner rotor that rotates around its axis with permanent magnets on it, • A permanent magnet whose surfaces are arranged in the order of the N and S poles facing the internal electromagnet, and the magnetic field created by the electromagnet is constantly changing, creating a pulling and pushing force and allowing the internal rotor to rotate,

• An internal electromagnet, which forms the internal stator, where a constantly changing magnetic field is created,

• The external electromagnet, which forms the stator unit between the middle rotor and the outer rotor, applies a repulsive and attractive force to the permanent magnets in the middle rotor and outer rotor with the changing magnetic field created in the stator windings and enables rotational movement,

• A middle rotor, which is placed between the inner and outer electromagnet and on which permanent magnets are placed, and one side of the permanent magnets is facing the inner electromagnet/stator, while the other side is facing towards the outer electromagnet/stator,

• An external rotor (5), which rotates with force applied to the permanent magnets on it by means of the magnetic field created by the external electromagnet,

• An external electromagnet holder with bearings carrying the pins of the outer electromagnet,

• Movable middle and outer rotor holder-2, which holds the middle and outer rotor and has bearings on it,

• The inner electromagnet cover, which holds the inner electromagnet and has bearings on it,

• Inner and outer rotor connecting flywheel connecting the inner rotor with the middle and outer rotor holder.

The structural and characteristic features and all advantages of the invention outlined in the drawings below and in the detailed description made by referring to these figures will be understood clearly; therefore, the evaluation should be made by taking these figures and detailed explanation into consideration.

Brief Description of the Figures Figure 1 shows the perspective and cross-section views of the brushless electric motor.

Figure 2 shows the detailed views of the brushless electric motor.

Figure 3 shows the perspective and cross-section views of the inner shaft.

Figure 4 shows the perspective and cross-section views of the inner electromagnet.

Figure 5 shows the perspective and cross-section views of the outer electromagnet.

Figure 6 shows the perspective and cross-section views of the middle rotor.

Figure 7 shows the perspective and cross-section views of the outer rotor.

Figure 8 shows the perspective view of the outer electromagnetic rotor holder.

Figure 9 shows the perspective and cross-section views of the middle and outer rotor holder.

Figure 10 shows the perspective views of the middle and outer rotor holder.

Figure 11 shows the perspective views of the electromagnet cover.

Figure 12 shows the perspective views of the inner and outer rotor flywheel.

Figure 13 shows the perspective view of the ring.

Figure 14 shows the perspective view of the bearings.

Figure 15 shows the perspective view of the bolts.

Figure 16 shows the perspective view of the fixing apparatus.

Figure 17 shows the perspective view of the wedges.

The drawings do not necessarily have to be scaled, and the details that are not necessary to understand the invention may be neglected. Other than that, elements that are substantially identical, or at least have substantially identical functions, are denoted by the same number.

Reference Numbers

1. Inner Rotor

1.1 Permanent magnet

2. Inner electromagnet

2.1 Cores

2.2 Windings

2.3 Fixing pins

3. Outer electromagnet 3.1 Cores

3.2 Windings

3.3 Fixing pins

4. Middle Rotor

4.1 Permanent magnet

4.2 Screw (guide) drilled holes

11. Outer rotor

5.1 Permanent magnet

5.2 Gear wheels

5.3 Screw (guide) drilled holes

6. Outer electromagnet holder

6.1 Pin bearings

7. Middle and Outer Rotor holder

7.1 Bolt holes

7.2 Permanent magnet

8. Middle and Outer Rotor holder-2

8.1 Middle rotor holder

8.2 Outer rotor holder

8.3 Permanent magnets

9. Inner electromagnet cover

10. Inner and outer rotor connecting flywheel

11. Ring

12. Bearings

13. Bolts

14. Fixing element

15. Wedges

Detailed Description of the Invention

In this detailed description, the preferred structures of the invention are explained only for a better understanding of the subject matter and without any restrictive effect.

The invention relates to a brushless electric motor with a hybrid rotor and stator topology. Figure 3 shows the structure of the inner rotor (1) from the side and front. The inner rotor (1) includes permanent magnets (1.1) fixed on it at an identical distance. The permanent magnets (1.1) on the inner rotor (1) are arranged so that they are N and S, respectively. The structures of the middle rotor (4) and the structure of the outer rotor (5) are shown in figure 6 and figure 7, respectively. The permanent magnets (4.1) on the middle rotor (4) are placed at the same angle and opposite pole as the permanent magnets (1.1) in the inner rotor. Similarly, the permanent magnets (5.1) on the outer rotor (5) are placed at the same angle and opposite pole as the permanent magnets

(4.1) in the middle rotor (4).

The inner electromagnet (2) (stator) is fixed between the inner rotor (1) and the middle rotor (4), and the outer electromagnet (3) (stator) is fixed between the middle rotor (4) and the outer rotor (5). Stator windings are wound in such a way that they have a three- phase winding structure. An electromagnet is formed by the electric current applied in the windings (2.2 and 3.2) wrapped in the cores (2.1 and 3.1) of the stators (2, 3). The N and S poles of the magnet formed in the windings (2.2 and 3.2) are continuously adjusted with a three-phase inverter control circuit according to the poles of the permanent magnets fixed to the rotors. This way, constant pulling and pushing forces are applied to the permanent magnets to ensure that the motor rotates at the desired speed.

Another contribution of the invention is that permanent magnets (7.2) in axial form have been added to the middle and outer rotor holders (7) to make greater use of the electromagnet's magnetic field. The permanent magnets here are arranged so that the surfaces of the permanent magnets (4.1 , 5.1) on the middle and outer rotor (4, 5) are at the same pole as the surfaces facing the stator. Thus, along with the magnetic force applied to the middle and outer rotor (4, 5), a more powerful motor structure was obtained by applying pressure to the permanent magnets on the axial rotor.

Separate explanations of the elements used in the system of the invention are given below.

Inner Rotor (1): An element rotating around its axis that houses permanent magnets

(1.1) on it.

Permanent magnet (1.1): Magnets with one side N and the other S pole. The surfaces of the magnets are arranged in the order of N and S poles facing the inner electromagnet (2). The magnetic field created by the electromagnet is constantly changing, creating a pulling and pushing force on the permanent magnets and ensuring the rotation of the inner rotor (1).

Inner electromagnet (2): The internal stator unit that generates a constantly changing magnetic field. The direction of the magnetic field created by the internal stator is constantly changed with an electronic drive according to the position state of the rotor.

Cores (2.1): An iron core in a laminated structure in which windings are wound to create a magnetic field. Although the cores are usually made of Si-Fe alloy material, amorphous materials can be preferred in recent years.

Windings (2.2): The electrical conductors through which electric current passes and a magnetic field is created. These windings can be copper, aluminum, or superconducting materials.

Fixing pins (2.3): The elements that attach to the inner electromagnet (2) cover and secure the inner electromagnet.

Outer electromagnet (3): The stator unit between the middle rotor (4) and the outer rotor (5). With the changing magnetic field created in the stator windings, a pushing and pulling force is applied to the permanent magnets (4.1 , 5.1) in the middle rotor (4) and the outer rotor (5), and the rotational movement is performed.

Cores (3.1): The iron cores in the laminated structure where a magnetic field is created.

Windings (3.2): The conductive cables through which an electric current flows create a magnetic field.

Fixing pins (3.3): The elements that attach to the outer electromagnet (3) holder and secure the outer electromagnet.

Middle rotor (4): The rotating unit which has permanent magnets (4.1) on it and is placed between the inner and outer electromagnet (2, 3). While one side of the fixed/permanent magnets (4.1) in this unit is towards the inner electromagnet/stator (2), the other side is towards the outer electromagnet/stator (3). The magnetic fields created in the inner and outer stator simultaneously create a magnetic force on the permanent magnets on the rotor and increase the rotational power. Permanent magnets (4.1): The permanent magnets with one surface are N and the other S pole. These magnets are arranged so that the magnets in the inner rotor (1) will have opposite poles.

Screw (guide) drilled holes (4.2): The elements that allow the middle rotor (4) to be fixed with the Middle and Outer Rotor holder (7) and the Middle and Outer Rotor holder-2 (8) through the bolts (13).

Outer Rotor (5): An element rotating around its axis that houses permanent magnets (5.1) on it. Permanent magnets (5.1) rotate with the applied force due to the magnetic field created by the outer electromagnet (3).

Permanent magnet (5.1): These magnets are arranged in such a way that the S and N pole surfaces are aligned. The magnets on the outer rotor (5) are arranged so that they will have opposite poles to the magnets on the middle rotor (4).

Gear wheels (5.2): This element is changeable, and a gear wheel (5.2), pulley, or impeller can be installed on the outer rotor (5). In this design of the invention, the gear wheel (5.2) is preferably used. The motion can be used for power and torque transmission, as well as the thrust force can be obtained by attaching the propeller.

Screw (guide) drilled holes (5.3): The elements that allow the outer rotor (5) to be fixed with the Middle and Outer Rotor holder (7) and the Middle and Outer Rotor holder-2 (8) through the bolts (13).

The outer electromagnet holder (6): The element that houses the bearing (12) on it and carries the pins of the outer electromagnet (3).

Pin bearings (6.1): The elements that bear the fixing pins of the outer electromagnet (3).

Middle and Outer Rotor holder (7): The movable element that holds the middle and outer rotor (4, 5) and has bearings (12) on it.

Bolt holes (7.1): The elements that allow the middle and outer rotor (4, 5) to be fixed through bolts (13).

Permanent magnets (7.2): The magnets that are placed in axial sections to make more use of the magnetic field created in inner and outer electromagnets (2, 3). These magnets are placed so that they are located on the ledge of the internal and external stator cores (2.1 , 3.1), which allows for making more use of the magnetic field. This increases the engine power.

Middle and outer rotor holder-2 (8): The element that holds the middle and outer rotor (4, 5) and contains a bearing (12) and a permanent magnet on it.

Middle rotor holder (8.1): The elements containing permanent magnets (8.3) on which the middle rotor (4) is held utilizing bolts (13).

Outer rotor holder (8.2): The element that holds the outer rotor (5) through the bolts (13).

Permanent magnets (8.3): The permanent magnets that are placed in the axial zone.

Inner electromagnet cover (9): This is the element that holds the inner electromagnet (2) and houses the bearings (12) on it.

Inner and outer rotor connecting flywheel (10): The element that connects the inner rotor (1) and the middle and outer rotor holder (7).

Ring (11): The element that fixes the inner electromagnet cover (9) and prevents it from moving along the axis.

Bearings (12): These are the elements that support the inner, middle, and outer rotors (1 , 4, 5), the inner electromagnet cover (9), and the outer electromagnet holder (6).

Bolts (13): The detachable joining elements.

Fixing apparatus (14): The element that keeps the inner electromagnet cover (9) and the outer electromagnet holder (6), keeping them stable.

Wedges (15): A detachable fastener that secures the inner and outer rotor connecting flywheel (10).