Armature winding, preparation method thereof and coreless cup motor

Abstract

The present invention discloses an armature winding, a preparation method thereof and a hollow cup motor, belonging to the field of motors. It includes an armature core and a three-phase winding. The armature core is a circular ring structure; the three-phase winding includes three coil groups that are tightly fitted along the inner wall of the armature core in the circumferential direction, the coil group is composed of two single coils that are mirror-distributed about the axis of symmetry of the armature core, and the two single coils are connected in series. The cylindrical winding is shaped so that the middle winding of the three-phase winding is tightly fitted to the inner wall of the armature core, and the upper and lower end windings of the three-phase winding form an oblate cylinder and are tightly attached to the upper and lower end surfaces of the armature core to form an oblate cylinder. Both ends of the armature winding of the present invention are shaped toward the outside of the center of the circle, and the two ends are tightly attached to the upper and lower surfaces of the armature core. The motor axial direction is in a vertical state, which minimizes the end length, shortens the motor length under the same output power, and has a more compact structure.

Description

Technical Field

[0001] The invention belongs to the field of motors, in particular to an armature winding, a preparation method thereof and a coreless cup motor. Background Art

[0002] Coreless motors have outstanding advantages such as no cogging, high power density, and low loss. Coreless motor windings can be divided into oblique windings, straight windings, diamond windings, etc. according to the winding form. Under the same parameters, the energy conversion rate of the straight winding armature will be higher.

[0003] As attached Figure 1 As shown in the figure, the A1 and A2 segments are the ends, and the middle segment B is the effective winding part, which is characterized by thicker ends and thinner middle part. Then the cylindrical winding is shaped by tooling as shown in the attached figure. Figure 2 The form is characterized in that the end winding of section A1 is shaped inwardly toward the center of the circle, the end winding of section A2 is shaped outwardly toward the center of the circle, and the height of section A1 winding is higher than that of section A2 winding. Figure 3 As shown, the shaped winding can be installed into the stator core and further assembled into a complete motor.

[0004] Through research, the applicant found that the traditional hollow cup armature straight winding has the following disadvantages: 1. The straight winding armature coil is 180-degree cross-wire wound, and the end winding is relatively long, which affects the overall length of the motor; 2. The end of the winding that is shaped toward the center of the circle is relatively high, which increases the length of the motor; 3. Since one end is shaped toward the center of the circle, the remaining aperture is relatively small, resulting in the rotor part having to pass through the shaft before the bearing is installed, which makes assembly more difficult; 4. The coil is shaped separately and then installed into the stator core, which may result in poor concentricity of the winding after assembly, resulting in an increase in the harmonic content of the motor's back electromotive force, affecting the motor performance. Summary of the invention

[0005] In order to overcome the above technical defects, the present invention provides an armature winding, a preparation method thereof and a coreless motor to solve the problems involved in the background technology.

[0006] In a first aspect, the present invention provides an armature winding, comprising:

[0007] The armature core is a ring structure;

[0008] The three-phase winding comprises three coil groups which are closely fitted along the circumference of the inner wall of the armature core. The coil group is composed of two single coils which are distributed in a mirror image with respect to the symmetry axis of the armature core. The two single coils are connected in series. The cylindrical winding is shaped so that the middle winding of the three-phase winding is closely fitted to the inner wall of the armature core. The upper and lower end windings of the three-phase winding form an oblate cylinder and are closely attached to the upper and lower end surfaces of the armature core to form an oblate cylinder.

[0009] Preferably or optionally, the armature core is a collection of silicon steel sheets with uniform magnetic resistance in each radial direction, and insulating material is coated on the inner diameter and end surface of the armature core.

[0010] Preferably or optionally, the single coil is formed by winding a plurality of turns of self-adhesive enameled wire.

[0011] Preferably or optionally, the coil group occupies a 120 degree arc in the winding annular area inside the armature core;

[0012] In a second aspect, the present invention provides a method for manufacturing an armature winding, comprising:

[0013] Step 1, cyclically winding at least one strand of enameled wire for a predetermined number of turns in a concentric circle arrangement manner to form a flat single coil; the winding span of the end windings on both sides of the single coil is less than 180 degrees;

[0014] Step 2, continue to use the enameled wire or another enameled wire electrically connected to the enameled wire to cyclically wind a predetermined number of turns in a concentric circle routing manner to form another single coil; then place the symmetry axes of the two single coil groups in mirror image to form a coil group;

[0015] Step 3, repeat steps 1 to 2 to obtain three coil groups; then closely fit the three coil groups in sequence to form a cylindrical structure, and set coil group outgoing wires on the end windings on the same side of the three coil groups to form a three-phase winding;

[0016] Step 4: insert the three-phase winding into the armature core and fix it so that the middle winding of the three-phase winding is closely fitted to the inner wall of the armature core;

[0017] Step 5: shaping the two sides of the three-phase winding, wherein the upper and lower end windings of the three-phase winding form a flat cylinder and are closely attached to the upper and lower end surfaces of the armature core to form a flat cylinder.

[0018] Preferably or optionally, the coil group occupies an arc angle of 120 degrees in a winding ring area inside the armature core.

[0019] Preferably or optionally, one side of the coil group is evenly distributed within a 60 degree circumference around the center of the armature core.

[0020] Preferably or optionally, the winding span of the end winding of the single coil is 150 degrees.

[0021] In a third aspect, the present invention further provides a coreless motor, comprising:

[0022] The shell is a hollow cylindrical cavity composed of a front cover, a rear cover and a side surface;

[0023] An armature winding having the above-mentioned armature winding structure, or an armature winding obtained by the above-mentioned preparation method; fixedly installed in the cavity, the central axis of the armature core coincides with the central axis of the housing;

[0024] The rotor is a motor rotor with a permanent magnet, which is located on the central axis of the armature core and can rotate freely along the central axis of the shell.

[0025] Preferably or optionally, the front end cover and the rear end cover are both provided with bearings, and the rotor is installed on the housing through the bearings.

[0026] Preferably or optionally, a corrugated spring is arranged between the bearing on the rear end cover and the rear end cover.

[0027] The present invention relates to an armature winding, a preparation method thereof and a coreless cup motor, which have the following beneficial effects compared with the prior art:

[0028] 1. Since both ends of the armature winding are shaped toward the outside of the center of the circle, the two ends are close to the upper and lower surfaces of the armature core, and the motor axis is in a vertical state, which minimizes the end length, shortens the motor length under the same output power, and makes the structure more compact;

[0029] 2. Since both ends of the armature winding are shaped toward the outside of the center of the circle, the through holes at both ends are consistent, the rotor is easy to install and the motor assembly process is simple;

[0030] 3. Since the motor winding enters the armature core first and then the inner diameter and end are shaped, the concentricity of the coil inner diameter and the core can be ensured, the motor harmonic content can be reduced, and the motor efficiency and stability can be improved.

[0031] 4. High-temperature insulating tape is wrapped around the outer circles of both ends of the armature winding, which can not only make the winding installation smooth, but also protect the armature winding from being scratched by the sharp edges of the armature core, reducing the probability of damage during the motor production process.

[0032] 5. The winding span of each single coil of the three-phase coil group is 150 degrees, and the coil group occupies an arc angle of 120 degrees in the winding ring area, and is evenly distributed around the 60-degree circumference of the armature center. This not only can obtain the same back electromotive force as the 180-degree span, but also reduces the end winding length, shortens the overall length of the motor, and reduces the internal resistance, thereby improving the energy conversion efficiency of the armature. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 It is a schematic diagram of the structure of the initial winding of the hollow cup motor.

[0034] Figure 2 It is a schematic diagram of the structure of the traditional hollow cup motor formed winding.

[0035] Figure 3 This is the assembly diagram of the traditional hollow cup motor formed winding and armature core.

[0036] Figure 4 It is a structural schematic diagram of a complete armature in the present invention.

[0037] Figure 5 It is a structural schematic diagram of the three-phase winding in the present invention.

[0038] Figure 6 It is a structural schematic diagram of the coil group in the present invention.

[0039] Figure 7 It is a structural schematic diagram of a single coil in the present invention.

[0040] Figure 8 It is a schematic diagram of the cross-line of three coil groups in the present invention.

[0041] Fig. 9 It is a schematic diagram of the structure of the initial winding including the high temperature insulating tape in the present invention.

[0042] Fig.10 It is a schematic diagram of the structure of the armature winding inserted into the iron core in the present invention.

[0043] Fig.11 It is a schematic diagram of the shaping process of the three-phase winding in the present invention.

[0044] Fig.12 It is a structural schematic diagram of the hollow cup motor in the present invention.

[0045] The figures are marked as: armature core 100, three-phase winding 200, coil group 210, single coil 211, effective winding 211a, end winding 211b, flat cylinder 220, coil group outlet 230, front end cover 300, rear end cover 400, rotor 500, bearing 600, corrugated spring 700, high temperature insulating tape 800, and shaping mold 900. DETAILED DESCRIPTION

[0046] In the following description, a large number of specific details are provided to provide a more thorough understanding of the present invention. However, it is apparent to those skilled in the art that the present invention can be implemented without one or more of these details. In other examples, in order to avoid confusion with the present invention, some technical features well known in the art are not described.

[0047] As attached Figure 1 As shown, the A1 and A2 segments are end windings 211b, and the middle segment B is an effective winding 211a, which is characterized by thicker ends and thinner middle part. Then, the cylindrical winding is shaped as shown in the attached figure. Figure 2The form is characterized in that the end winding 211b of the A1 section is shaped inwardly toward the center of the circle, the end winding 211b of the A2 section is shaped outwardly toward the center of the circle, and the height of the A1 section winding is higher than that of the A2 section winding. Figure 3 As shown, the shaped winding can be installed into the armature core 100 and further assembled into a complete motor.

[0048] Through research, the applicant found that the traditional hollow cup armature straight winding has the following disadvantages: 1. The straight winding armature coil is 180-degree cross-wire wound, and the end winding 211b is relatively long, which affects the overall length of the motor; 2. The end of the winding that is shaped toward the center of the circle is relatively high, which increases the length of the motor; 3. Since one end is shaped toward the center of the circle, the remaining aperture is relatively small, resulting in the rotor 500 having to pass through the shaft before the bearing 600 is installed during assembly, which makes assembly more difficult; 4. The coil is shaped separately and then installed into the armature core 100, which may result in poor concentricity of the winding after assembly, resulting in an increase in the harmonic content of the motor's back electromotive force, affecting the motor performance.

[0049] Example 1

[0050] This embodiment provides an armature winding. Figures 4 to 8 The armature winding includes: an armature core 100 and a three-phase winding 200. The armature core 100 is a ring structure; the armature core 100 is a collection of silicon steel sheets with uniform magnetic resistance in each radial direction, and the inner diameter and end surface of the armature core 100 are coated with insulating material.

[0051] The three-phase winding 200 includes three coil groups 210 that are tightly fitted along the circumference of the inner wall of the armature core 100. The three coil groups 210 form a cylindrical winding. The cylindrical winding is tightly fitted to the inner wall of the armature core 100 through a shaping process. The coil group 210 is composed of two single coils 211 that are mirror-distributed about the symmetry axis of the armature core 100; and the two single coils 211 are connected in series, and the winding span of the single coil 211 at both ends of the armature core 100 is less than 180 degrees.

[0052] Among them, the straight winding in the middle of the single coil 211 corresponding to the armature core 100 is the effective winding 211a, and the bent part of the upper and lower ends of the single coil 211 connected across the line is the end winding 211b. The cylindrical winding is shaped so that the effective winding 211a of the three-phase winding 200 is closely fitted with the inner wall of the armature core 100, and the upper and lower end windings 211b of the three-phase winding 200 form an oblate cylinder 220, and are closely attached to the upper and lower end surfaces of the armature core 100 to form an oblate cylinder 220. Since both ends of the armature winding are shaped toward the outside of the center of the circle, the through holes at both ends are consistent, the rotor 500 is easy to install, and the motor assembly process is simple. Of course, a wiring plug 230 is provided on one side of the end winding 211b, and the coil group outlet 230 is connected to both ends of the coil group 210 and connected to an external power supply.

[0053] In a further embodiment, the single coils 211 are formed by winding a plurality of turns of self-adhesive enameled wire. Moreover, two single coils 211 in the same coil group 210 are connected in series. During the winding process, a single self-adhesive enameled wire is wound a certain number of times to form a single coil 211, and then one end of the single coil 211 is rewound with a new single coil 211 to form a complete coil group 210. Figure 8 , Figure 8 The schematic diagram of the coil group cross-wire is a unique wiring method that shortens the cross-wire length at the end, maximizes the use of space, reduces the internal resistance of the motor, and improves the thermal conductivity of the motor winding, thereby greatly improving the power density and overall performance of the motor. Among them, the two single coils 211 are wound independently to avoid winding cross-wires and do not interfere with each other in space.

[0054] In a further embodiment, the armature core 100 and the armature winding are connected by a high-temperature insulating tape 800. Specifically, the high-temperature insulating tape 800 is wound around the outer circumference of both ends of the armature winding, and the high-temperature insulating tape 800 is just located at the corner where the inner surface of the armature core 100 intersects with the upper and lower end surfaces, wherein the high-temperature insulating tape 800 is made of polyimide material. The smooth outer surface of the high-temperature tape of polyimide material not only reduces the difficulty of assembly, but also avoids the risk of the winding being scratched by the sharp edge of the armature core 100, thereby reducing the risk of production damage.

[0055] In order to facilitate understanding of the technical solution of the armature winding, a method for manufacturing the armature winding is further described. The manufacturing method comprises the following steps:

[0056] Step 1, cyclically winding at least one strand of enameled wire for a predetermined number of turns in a concentric circle manner to form a flat single coil 211; the winding span of the end windings 211b on both sides of the single coil 211 is less than 180 degrees;

[0057] Step 2, continue to use the enameled wire or another enameled wire electrically connected to the enameled wire to cyclically wind a predetermined number of turns in a concentric circle routing manner to form another single coil 211; then place the two single coil 211 groups 210 in a mirror image along the axis of symmetry to form a coil group 210;

[0058] Step 3, repeat steps 1 to 2 to obtain three coil groups 210; then the three coil groups 210 are closely fitted in sequence to form a cylindrical structure, and coil group outgoing wires 230 are arranged on the end windings 211b on the same side of the three coil groups 210 to form a three-phase winding 200;

[0059] Step 4: insert the three-phase winding 200 into the armature core 100 and fix it so that the middle winding of the three-phase winding 200 is closely attached to the inner wall of the armature core 100;

[0060] Step 5: The inner diameter and the end of the three-phase winding 200 are shaped by the shaping mold 900. The upper and lower end windings 211b of the three-phase winding 200 form an oblate cylinder 220 and are closely attached to the upper and lower end surfaces of the armature core 100 to form an oblate cylinder 220; the concentricity of the inner diameter of the coil and the armature core 100 is ensured, the harmonic content of the motor is reduced, and the efficiency and stability of the motor are improved. The shaping mold 900 is used in the shaping process. The shaping mold 900 includes a T-shaped sleeve at the bottom, an end cover arranged above the T-shaped sleeve, and the external space formed by the T-shaped sleeve and the end cover is used to place the three-phase winding 200.

[0061] In a further embodiment, by designing the winding method of the three-phase coil group 210, the winding span of each single coil 211 is 150 degrees, and the coil group 210 occupies a 120-degree arc angle in the winding ring area, and is evenly distributed around the 60-degree circumference of the armature center. In this way, not only can the same back electromotive force as the 180-degree span line be obtained, but the length of the end winding 211b is reduced, the overall length of the motor is shortened, and the internal resistance is reduced, thereby improving the energy conversion efficiency of the armature.

[0062] In a further embodiment, step 4 further includes: pre-winding high temperature insulating tape 800 around the outer circumference of both ends of the three-phase winding 200, and then sleeve the three-phase winding 200 inside the armature core 100, so that the high temperature insulating tape 800 is just located at the corner where the inner wall of the armature core 100 intersects with the upper and lower end surfaces. The high temperature insulating tape 800 is made of polyimide material. The smooth outer surface of the high temperature tape of polyimide material not only reduces the difficulty of assembly, but also avoids the risk of the winding being scratched by the sharp edge of the armature core 100, reducing the risk of production damage.

[0063] Embodiment 2,

[0064] Based on Example 1, this embodiment proposes a hollow cup motor. Figures 4 to 12 The coreless cup motor comprises: a housing, an armature core 100, an armature winding and a motor rotor 500 with a permanent magnet.

[0065] The housing is a hollow cylindrical cavity consisting of a front cover 300, a rear cover 400 and a side surface; the armature core 100 is fixedly installed in the hollow cavity, and the central axis of the armature core 100 coincides with the central axis of the housing; the armature core 100 is a hollow cylindrical structure; the armature winding is connected to the armature core 100; its two ends are bent outwardly of the center of the armature core 100, and the two ends of the armature winding are closely attached to the upper and lower surfaces of the armature core 100, and are in a vertical state with the motor axis; the rotor 500 is located on the central axis of the armature core 100, and the front cover 300 and the rear cover 400 are both provided with bearings 600, and the rotor 500 is installed on the housing through the bearings 600, and the rotating shaft is a motor rotor 500 with a permanent magnet, which can rotate freely along the central axis of the housing. Since both ends of the armature winding are shaped toward the outside of the center of the circle, the two ends are close to the upper and lower surfaces of the armature core 100 and are perpendicular to the motor axis, the end length is minimized, the motor length is shortened under the same output power, and the structure is more compact; in addition, since both ends of the armature winding are shaped toward the outside of the center of the circle, the through holes at both ends are consistent, the rotor 500 is easy to install, and the motor assembly process is simple.

[0066] In a further embodiment, a corrugated spring 700 is provided between the bearing 600 on the rear end cover 400 and the rear end cover 400. Such a structure has compact size, a large stiffness range, and a strong buffering and vibration absorbing ability, thereby ensuring the stability of the hollow cup motor.

[0067] It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any suitable manner without contradiction. In order to avoid unnecessary repetition, the present invention will not further describe various possible combinations.

Claims

1. An armature winding, characterized in that: include: The armature core is a ring structure; The three-phase winding comprises three coil groups which are closely attached to the inner wall of the armature core in the circumferential direction, the coil group is composed of two single coils which are distributed in a mirror image with respect to the symmetry axis of the armature core, the two single coils are connected in series, and the three coil groups form a cylindrical winding, the cylindrical winding is formed by a shaping process so that the middle winding of the three-phase winding is closely attached to the inner wall of the armature core, and the upper and lower end windings of the three-phase winding form an oblate cylinder and are closely attached to the upper and lower end surfaces of the armature core; The single coil is formed by winding a plurality of turns of self-adhesive enameled wire, the winding span of the end winding of the single coil is 150 degrees, the coil group occupies an arc angle of 120 degrees in the winding ring area inside the armature core, and one side of the coil group is evenly distributed around the 60-degree circumference of the center of the armature core.

2. The armature winding according to claim 1, characterized in that The armature core is a collection of silicon steel sheets with uniform magnetic resistance in each radial direction, and insulating material is coated on the inner diameter and end surface of the armature core.

3. A method for manufacturing an armature winding according to claim 1 or 2, characterized in that: include: Step 1, cyclically winding at least one strand of enameled wire for a predetermined number of turns in a concentric circle arrangement manner to form a flat single coil; the winding span of the end windings on both sides of the single coil is 150 degrees; Step 2, continue to use the enameled wire or another enameled wire electrically connected to the enameled wire to cyclically wind a predetermined number of turns in a concentric circle routing manner to form another single coil; then place the symmetry axes of the two single coil groups in mirror image to form a coil group; Step 3, repeat steps 1 to 2 to obtain three coil groups; then closely fit the three coil groups in sequence to form a cylindrical structure, and set coil group outgoing wires on the end windings on the same side of the three coil groups to form a three-phase winding; Step 4: insert the three-phase winding into the armature core and fix it so that the middle winding of the three-phase winding is closely fitted to the inner wall of the armature core; Step 5: shaping the two sides of the three-phase winding, wherein the upper and lower end windings of the three-phase winding form a flat cylinder and are closely attached to the upper and lower end surfaces of the armature core.

4. The method for manufacturing an armature winding according to claim 3, characterized in that: The step 4 also includes: pre-winding high-temperature insulating tape around the outer circumference of both ends of the three-phase winding, and then inserting the three-phase winding into the armature core, so that the high-temperature insulating tape is just located at the corner where the inner wall of the armature core intersects with the upper and lower end surfaces.

5. A coreless motor, characterized in that: The invention is characterized by comprising: The shell is a hollow cylindrical cavity composed of a front cover, a rear cover and a side surface; An armature winding having the armature winding structure according to claim 1 or 2; fixedly mounted in the cavity, the central axis of the armature core coincides with the central axis of the housing; The rotor is a motor rotor with a permanent magnet, which is located on the central axis of the armature core and can rotate freely along the central axis of the shell.

6. The coreless motor according to claim 5, characterized in that: The front end cover and the rear end cover are both provided with bearings, and the rotor is installed on the housing through the bearings.

7. The coreless motor according to claim 5, characterized in that: A corrugated spring is arranged between the bearing on the rear end cover and the rear end cover.

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