Challenge the biggest technical challenge among motors for electric power steering systems - reducing cogging torque.
With the accumulated rich experience and original technical strength, we have overcome many difficulties.
The motor of the all-electric steering system is directly connected to the steering shaft and assists in the operation of the steering device, so it is good for saving fuel, but reducing the cogging torque is a major issue because the cogging torque affects the steering feeling. When we first entered the field of EPS (Electric Power Steering), we used a distributed winding that wraps copper wires across three poles. In order to reduce the cogging torque and ensure the output, a complex stator structure with high-density wound copper wire is required. Not only are the design requirements high, but the requirements for mass production manufacturing are even higher, and only a very strong manufacturer like Japan Denko (Nidec) can manufacture such a motor with its own comprehensive strength.
Although Japan Denco (Nidec) has started an EPS project, it still faces the dilemma of overly complex structure for mass production on the production line. Therefore, Japan Denco has developed a centralized winding type product with a simple coil structure. In addition, by matching with the centralized winding, the torque fluctuation is increased by high frequency through multi-polarization, and the cogging torque is reduced. The split core is a method in which coils are wound around the split core and then the cores are assembled. The method of splitting the cores and winding them separately makes full use of the space between the cores, so that the copper wire can be wound at a high density to achieve high output.
Centralized winding EPS motors are not only in mass production, but also in the field of small car applications, so the requirements for reducing cogging torque and improving mass production performance have also been further increased. In order to enhance the degree of design freedom of this type of motor, the structure has been significantly changed from a conventional ring magnet to a chip magnet. By designing the magnet to a more ideal shape, it is expected that the cogging torque will be reduced. In addition to the use of sheet magnets, the adhesive-free structure was changed to a non-adhesive structure that does not use adhesive to hold the magnet in place, thereby improving quality and productivity. In addition, in order to enhance the robustness of the production line, a certain amount of work has been put into the core construction, which can control the tolerances to a minimum when assembling the divided cores.
1st generation
Distributed windings (based on 4 poles of specified magnets)
An assembled core with an inner and outer core is used to reduce tooth hysteresis
Distributed winding type. Due to the external interface, the number of poles is limited, so distributed windings are used.
2nd generation
Centralized windings
Split the core
A coil is wound around each tooth to form the shape of a stator
Centralized winding and ring magnet type. It adopts a simple centralized winding method, which is suitable for mass-produced products.
3rd generation
Centralized windings
Split the core
A coil is wound around each tooth to form the shape of a stator
Centralized winding and sheet magnet type. The magnet shape is relatively free. Efforts are made to eliminate assembly errors.
Instructions from R&D personnel
The electric power steering system has a significant fuel saving effect compared to the previous hydraulic power steering system. With the continuous development of EV practical development, EPS has become one of the most critical technology fields in the automotive industry, and has a bright future. Japan Denco (Nidec) has invested its experience and technology in motor design, control, and mass production over many years to produce high-performance EPS motors in various important fields of the automotive industry. As an industry leader, Japan Denco (Nidec) has made outstanding contributions to reducing the energy consumption of automobiles.
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