A self-supporting winding with 12 coils and a manufacturing method thereof

Abstract

The present invention relates to a self-supporting winding system with 12 coils and a method for manufacturing the same. The winding system comprises 12 coils, with taps between adjacent coils located on the side of the coil that was wound first. The winding system is used with a four-pole rotor. Compared to existing technologies, the present invention offers advantages such as effectively controlling the total winding length of the winding machine and reducing interference between the front and rear coils and taps.

Description

Technical Field

[0001] The present invention relates to a motor winding and a manufacturing method thereof, and in particular to a self-supporting winding using 12 coils and a manufacturing method thereof. Background Art

[0002] Slotless motors are widely used in industries such as medicine, aerospace, and industrial automation. Because the stator lacks slots, the design and application of its windings are particularly unique compared to traditional slotted motors. A search revealed that U.S. Patent 4,543,507 first proposed a self-supporting coil with a cylindrical shape, making it easier to assemble with the slotless stator. Japanese Patent JP2002-281705A details the winding method for this self-supporting coil, which generally consists of several steps: winding, flattening, and rolling. Chinese Patent CN1960129A utilizes a concentric winding method to produce a similar hollow cup coil; unlike JP2002-281705A, its individual coils are wound concentrically, using a stacked, staggered method to create the corresponding winding.

[0003] The various winding schemes described above each utilize different methods for coil fabrication. Existing patents generally address coreless windings with three or six coils. However, for coreless windings with more than six coils (e.g., 12 coils), these methods present certain drawbacks. This is because the number of winding taps increases significantly as the number of coils increases. These taps are typically located between two coils, and if not positioned accurately, they may interfere with other coils. This increased number of taps also complicates winding wiring, as the input and output wires must be distinguished, increasing the risk of errors in coil connection. Ultimately, the number of lead wires required for multi-coil solutions increases significantly.

[0004] Further research revealed Chinese patent CN106340987A: For self-supporting windings like P2002-281705A, the coil conductors need to be closer to the coil centerline to achieve a greater back EMF, thereby improving motor performance. Therefore, increasing the number of turns per coil from 3 or 6 coils to 12 coils significantly reduces the number of turns per coil, allowing the conductors of each coil to be closer to their respective centerlines, thereby achieving a greater back EMF. Therefore, the proposed 12-coil self-supporting winding combined with a 4-pole rotor is used to improve motor performance.

[0005] For the above 12-coil self-supporting winding, the traditional winding method is as follows Figure 1As shown, a winding machine is used to wind the wire on a quadrilateral (or hexagonal) winding die. The left side of the winding die is usually connected to a single-axis winding device. After winding one coil C1 (Coil 1), the corresponding tap 1-2 (the wire to the right of C1) is drawn, and then winding of the second coil C2 begins. Figure 2 To complete the winding of 12 coils, the number of coils increases from 3 or 6 to 12, so the number of taps increases significantly. The taps are located between the front and rear coils. However, during the actual winding process, the production of taps will interfere with the winding of the next coil. Summary of the Invention

[0006] The purpose of the present invention is to overcome the defects of the above-mentioned prior art and to provide a self-supporting winding with 12 coils and a manufacturing method thereof.

[0007] The purpose of the present invention can be achieved by the following technical solutions:

[0008] According to one aspect of the present invention, a self-supporting winding with 12 coils is provided. The number of coils in the winding is 12, and the taps between adjacent coils are located on the side of the coil that has been wound first, and is used in conjunction with a four-pole rotor.

[0009] As a preferred technical solution, the tap includes a starting wire of the rear winding coil and a tail wire of the front winding coil, wherein the starting wire and the tail wire are long and short wires or wires of different colors.

[0010] As a preferred technical solution, the total length of the 12 coils is 2PI per circumference, each coil occupies PI / 6, and the coil span is PI / 2; where PI is π.

[0011] As a preferred technical solution, the 12 coils C1 to C12 are evenly distributed along the circumference.

[0012] As a preferred technical solution, the 12 coils include 24 lead wires and 12 tap nodes. The flattened strip windings are rolled into a circular winding, and the tap nodes are restored to a straight line state.

[0013] As a preferred technical solution, for a 4-pole rotor, the connection method of the three-phase winding is defined as follows:

[0014] For the A-phase winding, the lead wire 1-1 of coil C1 is the starting wire, passing through the tail wire 1-2 of coil C1 and connected to the tail wire of coil C4. After passing through coil C4, the starting wire of coil C4 is connected to the starting wire of coil C7. After passing through coil C7, the tail wire of coil C7 is connected to the tail wire of coil C10. After passing through coil C10, it is led out from the starting wire 10-1 of coil C10 to complete the A-phase winding.

[0015] For the B-phase winding, the lead wire 5-1 of coil C5 is the starting wire, passing through the tail wire 5-2 of coil C5 and connected to the tail wire of coil C2. After passing through coil C2, the starting wire of coil C2 is connected to the starting wire of coil C11. After passing through coil C11, the tail wire of coil C11 is connected to the tail wire of coil C8. After passing through coil C8, it is led out from the starting wire 8-1 of coil C8 to complete the B-phase winding.

[0016] For the C-phase winding, the lead 3-1 of coil C3 is the starting line, which passes through the tail line 3-2 of coil C3 and is connected to the tail line of coil C6. After passing through coil C6, it is connected to the starting line of coil C9 from the starting line of coil C6. After passing through coil C9, it is connected to the tail line of coil C12 from the tail line of coil C9. After passing through coil C12, it is led out from the starting line 12-1 of coil C12 to complete the C-phase winding.

[0017] As a preferred technical solution, the tail wire and the starting wire are connected by welding, the welding part forms a welding spot, and the welding spot and the lead wire are arranged on the outer circle side of the winding end.

[0018] As a preferred technical solution, the wire used to wind the winding is a round self-adhesive enameled wire, or a square self-adhesive enameled wire, or a multi-strand Litz wire made of self-adhesive material.

[0019] As a preferred technical solution, the winding also includes a PCB board, the starting wires of the 12 coils are arranged on the outside of the PCB board, the tail wires of the 12 coils are arranged on the inside of the PCB, and the 24 solder joints are evenly distributed on the inside and outside of the PCB.

[0020] According to another aspect of the present invention, a method for manufacturing the self-supporting winding using 12 coils is provided. First, after completing one coil, the tap is placed on the side of the completed coil.

[0021] Secondly, after winding, distinguish the starting line and tail line of the tap by long and short lines or different colors;

[0022] Finally, the flattened strip winding is rolled into a circular winding, and the tap node is restored to a straight line state.

[0023] Compared with the prior art, the present invention has the following advantages:

[0024] 1) The combination of 12 self-supporting coils and a 4-pole rotor can more effectively improve the winding's ability to generate back EMF, thereby improving motor performance;

[0025] 2) By controlling the position of the lead wire tap during the winding process, the total winding length of the winding machine can be effectively controlled, reducing the mutual interference between the front and rear coils and the tap;

[0026] 3) By distinguishing the starting and tail wires of the coils by different colors or lengths, the risk of incorrect connection during the winding wiring process can be effectively guaranteed;

[0027] 4) Combined with a 4-pole rotor, the total length of the 12 coils is designed to be 2PI of the winding circumference, with a single coil length of PI / 6 and a winding span of PI / 2, ensuring the winding's effective use of the magnetic field.

[0028] 5) After the winding is initially rolled, the tail wire of the tap is restored to a straight state. The above method can effectively control the end size of the winding;

[0029] 6) After the coil is connected, the welding points are distributed on the outer circumference of the winding end to control the axial size of the winding.

[0030] 7) The pads are arranged on both the inner and outer circles of the PCB to reduce the difficulty of soldering and wiring. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 The figure is a schematic diagram of the winding method of the existing 12 coils;

[0032] Figure 2 This is a schematic diagram of the winding of the existing 12 coils after winding is completed;

[0033] Figure 3 Schematic diagram of the winding method of the 12 coils of the present invention;

[0034] Figure 4 This is a schematic diagram of the winding of the 12 coils of the present invention after winding is completed;

[0035] Figure 5 Schematic diagram of the winding expansion of 12 coils of the present invention;

[0036] Figure 6 Schematic diagram of the windings of the 12 coils of the present invention after being rolled into a circle;

[0037] Figure 7 A schematic diagram of restoring the tap nodes of the windings of 12 coils of the present invention to a straight line;

[0038] Figure 8 Schematic diagram of the connection of the windings of 12 coils of the present invention;

[0039] Figure 9 Schematic diagram of the three-phase connection of the windings of 12 coils of the present invention;

[0040] Figure 10 is a schematic diagram of a four-pole rotor;

[0041] Figure 11 Schematic diagram of a PCB board for the windings of 12 coils of the present invention. DETAILED DESCRIPTION

[0042] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without inventive effort shall fall within the scope of protection of the present invention.

[0043] The present invention provides a self-supporting winding with 12 coils, comprising 12 coils C1 to C12, wherein the taps between adjacent coils are located on the side of the coil that has been wound first. Figure 3 To improve the tapping method, after completing a coil, the tap is placed on the side of the completed coil. In this way, even when winding the next coil, it will not interfere with the winding of the next coil, so the total length of the winding can be effectively controlled.

[0044] After winding, separate the starting line and tail line of the tap by long and short lines (or different colors), see Figure 4 , which is convenient for subsequent wiring processes, such as Figure 4 The middle taps of C1 and C2 have two lines, a solid line and a dotted line. The dotted line represents the end of C1, and the solid line represents the start of C2. The same is true for the subsequent coils.

[0045] Figure 5 This is a winding expansion diagram (for a 4-pole rotor). The total length of the 12 coils in the winding is 2PI per circumference, each coil occupies PI / 6, and the coil span is about PI / 2.

[0046] The flattened strip winding is rolled into a circle Figure 6 The circular winding has 24 lead wires and 12 tap nodes. Figure 7 Restoring the tapped nodes to a straight line helps control the end size of the winding and the wiring of the coil. Figure 7 It can be found that 12 coils C1 to C12 are evenly distributed along the circumference, and the starting line and the ending line of each coil are marked by a solid line and a dotted line.

[0047] Figure 8 The winding connection diagram is shown in Figure 2. Figure 9This is a winding connection diagram, which defines the connection method of the three-phase winding (for a 4-pole rotor). For the A-phase winding, the lead wire 1-1 of coil C1 is the starting wire, passing through the tail wire 1-2 of coil C1 and connected to the tail wire of coil C4. After passing through coil C4, the starting wire of coil C4 is connected to the starting wire of coil C7. After passing through coil C7, the tail wire of coil C7 is connected to the tail wire of coil C10. After passing through coil C10, it is led out from the starting wire 10-1 of coil C10 to complete the A-phase winding.

[0048] For the B-phase winding, the lead wire 5-1 of coil C5 is the starting wire, passing through the tail wire 5-2 of coil C5 and connected to the tail wire of coil C2. After passing through coil C2, the starting wire of coil C2 is connected to the starting wire of coil C11. After passing through coil C11, the tail wire of coil C11 is connected to the tail wire of coil C8. After passing through coil C8, it is led out from the starting wire 8-1 of coil C8 to complete the B-phase winding.

[0049] For the C-phase winding, the lead 3-1 of coil C3 is the starting line, which passes through the tail line 3-2 of coil C3 and is connected to the tail line of coil C6. After passing through coil C6, it is connected to the starting line of coil C9 from the starting line of coil C6. After passing through coil C9, it is connected to the tail line of coil C12 from the tail line of coil C9. After passing through coil C12, it is led out from the starting line 12-1 of coil C12 to complete the C-phase winding.

[0050] The connection wires between the two windings are fixed by welding. For example, the tail wire of C1 and the starting wire of C4 are connected by welding. The welding part forms a welding point. Figure 8 The solder joints and lead wires shown in the figure are arranged on the outer circle side of the winding end to control the axial dimension of the entire winding.

[0051] After completing the three-phase winding connection, 1-1 is the starting line of phase A, 10-1 is the ending line of phase A, 5-1 is the starting line of phase B, 8-1 is the ending line of phase B, 3-1 is the starting line of phase C, and 12-1 is the ending line of phase C. The three-phase winding can be connected in a Y or triangle shape as required.

[0052] The wire used for winding is usually round self-adhesive enameled wire, or square self-adhesive enameled wire, or multi-strand Litz wire made of self-adhesive.

[0053] Figure 10 This is a schematic diagram of a four-pole rotor. Four permanent magnets are evenly distributed on the rotor, and the magnets are magnetized radially to form an NS alternating rotor.

[0054] Figure 11For the PCB of the winding, another way to handle the winding end is to arrange the starting wires of the 12 coils in the winding on the outside of the PCB board, and the tail wires of the 12 coils in the winding on the inside of the PCB. In this way, the 24 solder joints can be evenly distributed on the inside and outside of the PCB. The connection method of the pads refers to Figure 9 After completing the connection of the phase winding, you can connect it in Y-type or triangle as needed. The square pad is the pad for the lead-out wire of the final three-phase line.

[0055] The foregoing description is merely a specific embodiment of the present invention, and the scope of protection of the present invention is not limited thereto. Any person skilled in the art will readily conceive of various equivalent modifications or substitutions within the technical scope disclosed herein, and such modifications or substitutions are intended to be encompassed by the scope of protection of the present invention. Therefore, the scope of protection of the present invention shall be subject to the scope of protection of the claims.

Claims

1. A self-supporting winding with 12 coils, characterized in that: The winding has 12 coils, each with 24 lead wires and 12 tap nodes. The taps include the starting wire of the rear-wound coil and the tail wire of the front-wound coil. The taps between adjacent front and rear coils are located in the area of ​​the front coil that has been wound first. The taps are moved forward relative to the center of the front and rear coils, reducing interference between the front and rear coils and the taps, and will not interfere with the winding of the next coil. The self-supporting winding is used with a four-pole rotor. The tail wires and starting wires of adjacent front and rear coils are connected by welding, and the welding parts form solder joints. The solder joints and lead wires are arranged on the outer circle side of the winding end. The winding also includes a PCB board, and solder pads are arranged on the inner and outer circles of the PCB. The starting wires of the 12 coils are arranged on the outer side of the PCB board, and the tail wires of the 12 coils are arranged on the inner side of the PCB, and the 24 solder joints are evenly distributed on the inner and outer sides of the PCB.

2. A self-supporting winding with 12 coils according to claim 1, characterized in that: The starting line and tail line are long and short lines or lines of different colors.

3. The self-supporting winding with 12 coils according to claim 1, characterized in that: The total length of the 12 coils is 2PI per circumference, each coil occupies PI / 6, and the coil span is PI / 2; where PI is π.

4. The self-supporting winding with 12 coils according to claim 1, characterized in that: The 12 coils C1 to C12 are evenly distributed along the circumference.

5. The self-supporting winding with 12 coils according to claim 1, characterized in that: After all 12 coils are wound, a strip winding is formed; the flattened strip winding is rolled into a round winding, and the tap node is restored to a straight line state.

6. The self-supporting winding with 12 coils according to claim 4, characterized in that: For a 4-pole rotor, define the connection method of the three-phase winding: For the A-phase winding, the lead wire 1-1 of coil C1 is the starting wire, which passes through the tail wire 1-2 of coil C1 and is connected to the tail wire of coil C4. After passing through coil C4, the starting wire of coil C4 is connected to the starting wire of coil C7. After passing through coil C7, the tail wire of coil C7 is connected to the tail wire of coil C10. After passing through coil C10, it is led out from the starting wire 10-1 of coil C10 to complete the A-phase winding. For the B-phase winding, the lead wire 5-1 of coil C5 is the starting wire, which passes through the tail wire 5-2 of coil C5 and is connected to the tail wire of coil C2. After passing through coil C2, it is connected to the starting wire of coil C11 from the starting wire of coil C2. After passing through coil C11, it is connected to the tail wire of coil C8 from the tail wire of coil C11. After passing through coil C8, it is led out from the starting wire 8-1 of coil C8 to complete the B-phase winding. For the C-phase winding, the lead 3-1 of coil C3 is the starting line, which passes through the tail line 3-2 of coil C3 and is connected to the tail line of coil C6. After passing through coil C6, it is connected to the starting line of coil C9 from the starting line of coil C6. After passing through coil C9, it is connected to the tail line of coil C12 from the tail line of coil C9. After passing through coil C12, it is led out from the starting line 12-1 of coil C12 to complete the C-phase winding.

7. The self-supporting winding with 12 coils according to claim 1, characterized in that: The wires used to wind the windings are round self-adhesive enameled wires, square self-adhesive enameled wires, or multi-strand Litz wires made of self-adhesive materials.

8. A method for manufacturing the self-supporting winding with 12 coils as claimed in claim 1, characterized in that: First, after completing a coil, place the tap within the area of ​​the completed previous coil; Secondly, after winding, distinguish the starting line and tail line of the tap by long and short lines or different colors; Finally, the flattened strip winding is rolled into a circular winding, and the tap node is restored to a straight line state.

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