High-speed three-phase hollow cup motor and manufacturing method thereof

Abstract

The application relates to the technical field of electric machines, in particular to a high-speed three-phase hollow cup electric machine and a manufacturing method thereof. The technical scheme is as follows: the electric machine comprises a motor shell, a coil support, three-phase hollow cup coils, a magnetic ring rotor and a rotating shaft, the three-phase hollow cup coils are made of three groups of flattened coils arranged in an equidistant circumferential array in a cross-laminated manner, wherein each group of flattened coils is made by flattening a coil wound in an odd number of layers, and after heat pressing and rounding, each group of flattened coils is wound into one turn, and the coil wire heads at the two ends are twisted together. The beneficial effect is that the three-phase hollow cup coils are obtained by adopting three groups of coils wound in an odd number of layers (preferably five layers) in a cross-laminated manner for rounding and shaping, the thickness of the hollow cup coils can be effectively improved, high-voltage, high-frequency and high-power control operation of the hollow cup coils is realized, the rotating speed and the power of the hollow cup electric machine are effectively improved, the weight is reduced under the same power, and the power density of the electric machine is improved by more than 30%.

Description

Technical Field

[0001] This invention relates to the field of motor technology, and in particular to a high-speed three-phase hollow cup motor and its manufacturing method. Background Technology

[0002] A coreless motor is a type of motor that uses an iron-free coil, offering advantages such as no core loss, high energy density, and minimal speed fluctuation. Traditional coreless motors use a single-layer wound coil, manufactured through processes like flattening and rounding. This results in a thin coil with weak magnetic force, severely limiting its operating power and making it unsuitable for high-speed, high-voltage applications. In environments with weight constraints and high speed requirements, such as drones or portable devices, this can severely restrict product performance. Summary of the Invention

[0003] The purpose of this invention is to provide a high-speed three-phase coreless motor and its manufacturing method, specifically a three-phase coreless motor capable of achieving high power and high speed, and its manufacturing method.

[0004] To achieve the above objectives, the present invention adopts the following technical solution: a high-speed three-phase hollow cup motor, comprising a motor housing, a coil frame, three-phase hollow cup coils, a magnetic ring rotor, and a rotating shaft. The three-phase hollow cup coils are fixed on the coil frame and installed inside the motor housing. The magnetic ring rotor is rotatably disposed inside the three-phase hollow cup coils. The rotating shaft is inserted into the magnetic ring rotor and rotatably connected to the motor housing through a bearing. The three-phase hollow cup coils are made by hot pressing and rounding three groups of flattened coils arranged in an equidistant circular array in a cross-layered manner. Each group of flattened coils is made by flattening a coil wound with an odd number of layers. After hot pressing and rounding, each group of flattened coils is wound into one loop, and the coil ends at both ends are twisted together.

[0005] Preferably, each set of flattened coils of the three-phase hollow cup coil is made by flattening a coil with five layers of winding.

[0006] A method for manufacturing a high-speed three-phase hollow cup motor involves first winding a coil using enameled wire. The wound coil consists of an odd number of layers, each wound in the same direction and close together. Each of the odd-numbered layers of winding has a free end at both ends. Next, the wound coil is flattened along its central axis and heat-pressed to form a flat coil. Corresponding to the free ends at the beginning and end of the wound coil, the flat coil also has a free end at both ends. Three sets of flat coils are arranged in an equidistant circular array relative to a circular heating column. The first end of each set of flat coils contacts the side of the heating column. At least three circular blocks are driven to shape the three sets of flat coils arranged around the heating column into a circular shape, so that the three sets of flat coils are formed in a cross-layered manner to obtain a three-phase hollow cup coil composed of three sets of coils distributed in an equidistant circular array. The two free ends of the first and last ends of each set of flat coils are twisted together for wiring. The three-phase hollow cup coil is installed in the motor housing and a magnetic ring rotor and shaft are installed to obtain a high-speed three-phase hollow cup motor.

[0007] Preferably, when winding the coil, the number of winding layers is five.

[0008] Preferably, when winding the coil, a single-wire or multi-wire winding method can be adopted. When winding a single wire, the diameter of the enameled wire is not less than 0.12mm. When winding multiple wires in parallel, the total cross-sectional area of ​​the multiple enameled wires is not less than the cross-sectional area of ​​the enameled wire with a diameter of 0.12mm.

[0009] Preferably, after the coil is wound, the coil is held by a coil clamp with 3M adhesive tape, or by attaching a layer of 3M adhesive tape to the inside of the coil before clamping, to prevent the coil from loosening. Then the coil is flattened and heat-pressed to form a flat coil.

[0010] Preferably, when the coil is flattened and hot-pressed after winding, the hot-pressing temperature is not lower than 120°C.

[0011] The beneficial effects of this invention are as follows: by using three sets of odd-numbered layers (preferably five layers) of coil wound in a cross-layered manner to form a three-phase hollow cup coil, the thickness of the hollow cup coil can be effectively increased, enabling high-voltage, high-frequency, and high-power control operation of the hollow cup coil. This can meet the requirements of 310V DC frequency conversion control and achieve operating parameters of frequency conversion of no less than 20,000 Hz and power of no less than 100W, effectively improving the speed, power, and power density of the hollow cup motor. Attached Figure Description

[0012] Appendix Figure 1 This is a schematic diagram of the disassembled structure of the high-speed three-phase hollow cup motor in the embodiment;

[0013] Appendix Figure 2This is a schematic diagram of the assembly structure of the high-speed three-phase hollow cup motor in the embodiment;

[0014] Appendix Figure 3 This is a schematic cross-sectional view of the high-speed three-phase hollow cup motor in the embodiment.

[0015] Appendix Figure 4 This is a schematic diagram of the flattened coil in the embodiment;

[0016] Appendix Figure 5 This is a top view of the three sets of flattened coils arranged around the heating column in preparation for rounding and shaping, as shown in the embodiment.

[0017] Appendix Figure 6 This is a schematic diagram of the stacking structure between the three sets of flattened coils after they have been cross-stacked and rounded in the embodiment.

[0018] Appendix Figure 7 This is a schematic diagram of the structure of the three-phase hollow cup coil after hot pressing and rounding in the embodiment. Detailed Implementation

[0019] Example 1, referring to Figure 1-7 A high-speed three-phase hollow cup motor includes a motor housing 1, a coil frame 2, a three-phase hollow cup coil 3, a magnetic ring rotor 4, and a rotating shaft 5. The three-phase hollow cup coil 3 is fixed on the coil frame 2 and installed inside the motor housing 1. The magnetic ring rotor 4 is rotatably disposed inside the three-phase hollow cup coil 3. The rotating shaft 5 is inserted into the magnetic ring rotor 4 and rotatably connected to the motor housing 1 through a bearing 6. The three-phase hollow cup coil 3 is made by hot pressing and rounding three sets of flattened coils arranged in an equidistant circular array in a cross-layered manner. Each set of flattened coils is made by flattening a coil wound with an odd number of layers. After hot pressing and rounding, each set of flattened coils is wound into one loop and the coil ends at both ends are twisted together.

[0020] In this embodiment, the three-phase hollow cup coil 3 is made by hot-pressing and rounding three sets of flattened coils in a cross-layered manner. The three sets of coils are arranged in an equidistant circular array, which makes the magnetic field generated by the hollow cup coil more uniform and stable, which is conducive to precise control of the rotation of the magnetic ring rotor 4. Each of the three sets of flattened coils is made by flattening a coil with an odd number of layers. The coil with an odd number of layers is preferably cylindrical. Through the odd number of layers of winding, there is a coil wire end at each end of the coil. After flattening, each end of the coil also has a free end of the coil wire. After hot pressing and rounding, the flattened coil is wound into one circle and the coil wire ends at the beginning and end can be twisted together for easy wiring. The coil with an odd number of layers of winding preferably has five layers of winding, and the enameled wire used to wind the coil is preferably enameled wire with a diameter of not less than 0.12mm. By flattening a five-layer wound coil and then cross-stacking the three flattened coils to form a three-phase hollow cup coil 3, the overall thickness of the three-phase hollow cup coil 3 is not less than 2.0mm. After actual testing, it meets the requirements of 310V DC frequency conversion control and can achieve frequency conversion control of not less than 20,000 Hz and operating parameters of more than 100W power. It can generate a magnetic field strength of more than 0.6 Tesla and achieve a high speed of 160,000 revolutions per minute.

[0021] The manufacturing method of the high-speed three-phase hollow cup motor in this embodiment is as follows: First, the coil is wound using enameled wire. The wound coil consists of an odd number of layers of coils wound in the same direction and close together. Each end of the odd-numbered layers of coil has a free end. Then, the wound coil is flattened along the central axis of the coil and hot-pressed to form a flat coil. Corresponding to the free ends of the wound coils at both ends, the flat coil also has a free end at both ends. Three sets of flat coils are arranged in an equidistant circular array relative to the circular heating column, and each... The first ends of the flat coils are in contact with the side of the heating column. At least three circular blocks are driven to round and shape the three sets of flat coils arranged around the heating column, forming a three-phase hollow cup coil composed of three coils arranged in an equidistant circular array. The two free ends of the first and last wires of each flat coil are twisted together for wiring. The three-phase hollow cup coil 3 is installed in the motor housing 1 through the coil frame 2, and a magnetic ring rotor 4 and a shaft 5 are installed to obtain a high-speed three-phase hollow cup motor. The coil is wound in five layers. Single-wire or multi-wire winding can be used. When winding with a single wire, the diameter of the enameled wire is not less than 0.12 mm. When winding with multiple wires, the total cross-sectional area of ​​the enameled wires is not less than the cross-sectional area of ​​the 0.12 mm diameter enameled wire.

[0022] In addition, after the coil is wound, use a coil clamp with 3M adhesive tape to hold the coil, or attach a layer of 3M adhesive tape to the inside of the coil before clamping it to prevent the coil from loosening. Then flatten the coil and heat press it to shape it into a flat coil. When flattening and heat pressing the wound coil, the heat pressing temperature should not be lower than 120°C.

[0023] Of course, the above are only preferred embodiments of the present invention and are not intended to limit the scope of application of the present invention. Therefore, any equivalent changes made to the principle of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for manufacturing a high-speed three-phase hollow cup motor, characterized in that: First, enameled wire is used to wind the coils. The coils are wound in an odd number of layers, in the same direction, and tightly packed together. Each coil with an odd number of layers has a free end at both ends. Then, the wound coils are flattened along the central axis and heat-pressed to form flat coils. Corresponding to the free ends at the beginning and end of the wound coils, the flat coils also have a free end at both ends. Three sets of flat coils are arranged in an equidistant circular array relative to the circular heating column, and each set of flat coils... The first end of each flat coil contacts the side of the heating column. At least three circular blocks are driven to shape the three sets of flat coils arranged around the heating column into a circular shape, so that the three sets of flat coils are formed into a circular shape in a cross-layered manner, resulting in a three-phase hollow cup coil composed of three sets of coils distributed in an equidistant circular array. The two free ends of the first and last ends of each set of flat coils are twisted together for wiring. The three-phase hollow cup coil is installed in the motor housing, and a magnetic ring rotor and shaft are installed to obtain a high-speed three-phase hollow cup motor.

2. The method for manufacturing a high-speed three-phase hollow cup motor according to claim 1, characterized in that: When winding the coil, five layers are wound.

3. The method for manufacturing a high-speed three-phase hollow cup motor according to claim 1, characterized in that: When winding the coil, a single-wire or multi-wire winding method can be used. When winding a single wire, the diameter of the enameled wire should not be less than 0.12mm. When winding multiple wires in parallel, the total cross-sectional area of ​​the multiple enameled wires should not be less than the cross-sectional area of ​​the enameled wire with a diameter of 0.12mm.

4. The method for manufacturing a high-speed three-phase hollow cup motor according to claim 1, characterized in that: After the coil is wound, use a coil clamp with 3M tape attached to hold the coil with your fingers, or attach a layer of 3M tape to the inside of the coil before clamping it to prevent the coil from loosening. Then flatten the coil and heat press it to shape it into a flat coil.

5. The method for manufacturing a high-speed three-phase hollow cup motor according to claim 4, characterized in that: When the coil is flattened and hot-pressed after winding, the hot-pressing temperature should not be lower than 120℃.

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