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Complete Analysis of Ten Mainstream Motors: Revealing Their Internal Structures!

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Ø Basic Principles And Classification Of Motors

 

A motor is a device that converts electrical energy into mechanical energy, mainly generating rotational torque through electromagnetic induction or magnetic field interaction. According to the working principle and application scenario, motors can be divided into:

 

motor 

 

Ø Analysis Of Ten Mainstream Motor Structures

 

Ⅰ. Superconducting Motor

 

Superconducting Motor

 

A superconducting motor is a motor that uses superconducting materials as windings or rotor elements. Compared with traditional motors, it has higher power density, higher efficiency and lower losses.

 

Superconducting materials can exhibit zero resistance and complete anti-magnetism ( Meissner effect ) at low temperatures , allowing motors to greatly reduce copper and iron losses and improve energy conversion efficiency.

Superconducting motors can achieve both light weight, small size and high power.

 

motor-1 

 

The mechanism of a superconducting motor

 

motor-2

 

motor-3

 

Ⅱ. Induction motor

 

Induction motor

 

motor-4 

 

Induction motor, also known as asynchronous motor, is an AC motor. It can be divided into single-phase and three-phase according to the number of power phases. The main structure of induction motor consists of two parts: stator and rotor. In addition, there are end covers, bearings, motor frame and other parts.

 

Schematic diagram of squirrel cage asynchronous motor

 

 

motor-5 

 

Tesla's first mass-produced electric car was the Roadster, which used a conventional three-phase AC induction motor.

 

The motor type is a three-phase four-pole induction motor with a rated voltage of 375V and high power and torque output. The peak power of the Roadster's induction motor reaches 185kW and the maximum speed reaches 14,000RPM; the peak power of the asynchronous induction motor reaches 215kW, the maximum speed reaches 13,000RPM, the maximum torque reaches 430Nm, and the power density reaches 2.25kW/kg. These parameters together give the Roadster excellent performance.

 

motor-6 

 

. Permanent magnet synchronous motor

 

PMSM

 

A permanent magnet synchronous motor is an AC motor in which the stator winding rotates synchronously with the permanent magnet rotor. It has high power density, high efficiency and excellent dynamic response characteristics. It is widely used in new energy vehicles, industrial automation, aerospace, home appliances and other fields.

 

motor-7 

 

Interior permanent magnet synchronous motor

 

. IPM motor and SPM motor

 

The difference between the two

 

motor-8 

 

IPM motor:

 

Interior Permanent Magnet (IPM) is an AC power motor in which super magnets made of rare earth materials are installed in the rotor slots and the coil winding (armature) is fixed to the stator. Compared with other IPM motors, it has high efficiency, high reliability, high torque and high power density.

 

SPM motor:

 

Also an AC powered motor configuration in which super magnets are mounted on the rotor surface. SPM motors also offer high torque, high efficiency and high reliability.

 

Like IPM motors, SPMs are also synchronous motors, but here the permanent magnet motor is mounted on the rotor surface and the armature is fixed to the stator. In SPMs, the reluctance torque is minimal, so the torque produced is less than that of IPM motors.

 

. Brushless DC motor

 

Brushless DC Motor

 

motor-9

 

 

A brushless DC motor is an electronically commutated DC motor that uses a Hall sensor or magnetic encoder to detect the rotor position and a controller (electronic driver) to regulate the current, achieving brushless operation.

 

Compared with traditional brushed DC motors (BDC), BLDC motors eliminate mechanical commutators and brushes , thus having the advantages of higher efficiency, longer life, lower noise and less maintenance . Therefore, they are widely used in electric vehicles, drones, home appliances, industrial automation, medical equipment and other fields .

 

. Brushed DC motor

 

Brushless DC Motor

 

A brushed DC motor is a DC motor that achieves commutation through a mechanical commutator (brush and commutator) . It relies on the carbon brush to contact the commutator to change the direction of the current continuously, thereby driving the rotor to rotate.

 

replaced by brushless DC motors (BLDC) in some applications , they are still widely used in many industrial and consumer devices due to their low cost, simple control and high starting torque.

 

motor-10 

 

The brushed DC motor technology pictured here is derived from a design based on an ironless rotor (self-supporting coils) combined with a precious metal or carbon-copper commutation system and rare earth or alnico magnets.

 

DC motor diagram

 

All DC motors consist of three main sub-assemblies:

1. Stator

2. Brush holder end cover

3. Rotor

 

motor-11

 

 

. Liquid-cooled motor

 

Liquid-Cooled Motor

 

Liquid-cooled motors are a type of motor that uses a liquid cooling system to control the motor temperature. Compared with traditional air-cooled motors, liquid-cooled motors have higher heat dissipation efficiency and can maintain stable operation under high power and high load conditions.

 

Liquid cooling systems usually use water cooling (containing ethylene glycol solution), oil cooling or other coolants. Cooling methods include cooling sleeves, built-in cooling channels, direct cooling of rotors or stators, etc.

 

Lucid engineers figured out that there are narrow magnetic "dead zones" between the windings, and that they could cut long, thin cooling channels in these dead zones without affecting the magnetic flux. These channels allow the cooling oil to carry more heat closer to where the heat is generated (in the copper). The oil flows out of these narrow channels through pinholes that spray the oil onto the exposed copper windings.

 

motor-12 

motor-13 

motor-14 

Huawei liquid-cooled motor

 

Intelligent oil cooling for precise heat dissipation, reducing the temperature of motor core components by 15°C Ability to withstand extreme conditions, ultra-quiet AI algorithm for system-level coupled simulation optimization Industry-leading 78dB NVH, library-level quietness and comfort.

 

. Reluctance Motor

 

Reluctance Motor

 

A reluctance motor is a motor that generates torque by using magnetic resistance. It has a simple structure, does not require permanent magnets, and is suitable for high temperature environments. It is efficient, reliable, and low cost. It is suitable for applications that require high torque density and high energy efficiency.

 

Reluctance motors are generally divided into two categories: synchronous reluctance motors (SynRM) and switched reluctance motors (SRM).

 

motor-15 

Switched Reluctance Motor

motor-16

 

 

. Stepper Motor

 

Stepper Motor

 

A stepper motor is a discretely controlled motor. Every time an electric pulse is input, the rotor rotates a fixed angle (step angle), thereby achieving precise position control.

 

motor-17

 

 

The main features of stepper motors:

Open-loop control can accurately position without feedback system. High torque and good stability at low speed are suitable for occasions requiring precise control. Simple structure and low cost are widely used in industrial automation and consumer electronics.

 

Common types of stepper motors include permanent magnet stepper motors (PM), variable reluctance stepper motors (VR), hybrid stepper motors (HB), etc.

 

. Axial Flux Motor

 

Axial Flux Motor

 

The axial flux motor is a special motor topology where the magnetic flux is oriented parallel to the motor shaft , unlike the traditional radial flux motor (where the flux is perpendicular to the shaft).

 

motor-18 

 

Main features of axial flux motors: High power density for applications that are sensitive to size and weight, such as electric vehicles and aerospace. Shorter magnetic paths reduce iron losses and improve efficiency. Flat and compact design is more suitable for integration into compact devices. Application areas: New energy vehicles (EV), aerospace electric aircraft propulsion systems, wind and hydropower generation, etc.

 


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