Linear motor stator structure, assembly process and linear motor

Abstract

The application provides a linear motor stator structure, an assembling process and a linear motor. The linear motor stator structure comprises a stator core, a plurality of annular windings with consistent winding directions are sequentially sleeved on the stator core in the axial direction, every adjacent three annular windings are connected with three-phase power supply of A, B and C to form a winding unit; each annular winding comprises a winding clamp, the winding clamp is a polygonal structure with the same number of edges as the support frame, a boss is arranged on each edge of the polygonal structure, the bosses on the edges are connected to form a coil bearing surface, the bottom of the coil bearing surface extends to both sides in the axial direction to form opposite limiting blocks; a coil is wound on the coil bearing surface, a potting adhesive layer is uniformly coated around the coil, and the two side edges of the potting adhesive layer are vertically aligned with the two sides of the coil bearing surface.

Description

Technical Field

[0001] This invention relates to a linear motor, specifically to a linear motor stator structure, assembly process, and the linear motor itself. Background Technology

[0002] Permanent magnet linear synchronous motors (PMSMs) possess advantages such as high thrust density, fast dynamic response, and high positioning accuracy, and have broad application prospects. A PMSM consists of a stator and a mover, with an air gap between them. The mover can move linearly relative to the stator on a cross-section perpendicular to its direction of motion. In practical applications, the toroidal winding, due to its coil plane being perpendicular to the motor's direction of motion, offers advantages such as no end crossing, small space occupation, and good mechanical strength, thus gaining widespread attention and application in PMSMs. Based on the relative positions of the toroidal winding and the magnet, PMSMs can be classified into external winding type and internal winding type. In the external winding type, the toroidal winding is located on the mover, and the magnet is located on the stator; in the internal winding type, the magnet is located on the mover, and the toroidal winding is located on the stator.

[0003] In the actual production and processing of motors, uniform air gap between the stator and rotor is a necessary condition for ensuring good motor operation. The air gap between the stator and rotor is essentially generated by the interaction of the ring winding and the magnet. It can be seen that the uniformity of the air gap between the ring winding and the magnet is determined by the accuracy of the entire assembly, which in turn depends on the accuracy of the parts. Therefore, ensuring the accuracy of each part is the key condition for ensuring the uniformity of the motor air gap.

[0004] However, due to the differences in the processing quality of parts from different motor manufacturers, it is difficult to achieve an ideal level of air gap control for the assembled motor.

[0005] In order to solve the above problems, people have been seeking an ideal technological solution. Summary of the Invention

[0006] The purpose of this invention is to address the shortcomings of existing technologies by providing a linear motor stator structure, assembly process, and linear motor.

[0007] To achieve the above objectives, the technical solution adopted by the present invention is as follows: The present invention provides a linear motor stator structure, including a stator core, wherein a plurality of annular windings with the same winding direction are sequentially sleeved on the stator core along the axial direction, and every three adjacent annular windings are respectively connected to three-phase power supplies A, B, and C to form a winding unit.

[0008] Each annular winding includes a winding clamp, which is a polygonal structure with the same number of sides as the support frame. Each side of the polygonal structure is provided with a boss, and the bosses on multiple sides are connected to form a coil bearing surface. The bottom of the coil bearing surface extends axially to both sides to form opposing limiting blocks. A coil is wound on the coil bearing surface, and a potting compound layer is uniformly covered around the coil. The two sides of the potting compound layer are vertically aligned with the two sides of the coil bearing surface.

[0009] Specifically, the toroidal winding is manufactured using the following process, which includes a winding step and a potting step.

[0010] The winding step includes: installing a left clamp and a right clamp on both sides of the winding clamp respectively, and fastening the left clamp, the winding clamp and the right clamp together by a locking assembly, so that the right side wall of the left clamp, the left side wall of the right clamp and the coil bearing surface of the winding clamp form a winding groove.

[0011] The coil is wound on the coil bearing surface to fill the winding groove until the height of the coil in the winding groove reaches the first preset height. Then the winding is stopped, and the locking assembly is opened to remove the left clamp and the right clamp to obtain the pre-made winding.

[0012] The left clamp has a groove on its right side that matches the left limiting block of the winding clamp, and the right clamp has a groove on its left side that matches the right limiting block of the winding clamp.

[0013] The potting step includes: installing a left mold and a right mold on the outside of the prefabricated winding, and fastening the left mold, the prefabricated winding and the right mold together by a locking assembly, so that the prefabricated winding is located in the sealed cavity formed by the left mold and the right mold;

[0014] The potting compound is injected from the potting port of the sealed cavity. When the liquid level of the potting compound reaches the second preset height, the injection of the potting compound is stopped, and the locking assembly is opened to remove the left clamp and the right clamp, thereby obtaining an annular winding covered with a potting compound layer.

[0015] The right mold has a first receiving cavity, and the first receiving cavity has a groove that matches the right limiting block of the winding clamp; the left mold has a second receiving cavity, and the second receiving cavity has a groove that matches the left limiting block of the winding clamp; the first receiving cavity and the second receiving cavity cooperate to form a sealed cavity for accommodating the pre-made winding; the right mold or the left mold has a filling port.

[0016] This invention provides an assembly method for a linear motor stator structure, comprising the following steps:

[0017] The manufacturing process of the toroidal winding includes a winding step and a potting step.

[0018] The winding step includes: installing a left clamp and a right clamp on both sides of the winding clamp respectively, and fastening the left clamp, the winding clamp and the right clamp together by a locking assembly, so that the right side wall of the left clamp, the left side wall of the right clamp and the coil bearing surface of the winding clamp form a winding groove.

[0019] The coil is wound on the coil bearing surface to fill the winding groove until the height of the coil in the winding groove reaches the first preset height. Then the winding is stopped, and the locking assembly is opened to remove the left clamp and the right clamp to obtain the pre-made winding.

[0020] The winding clamp is a polygonal structure with the same number of sides as the support frame. Each side of the polygonal structure has a boss, and the bosses on multiple sides are connected to form a coil bearing surface. The bottom of the coil bearing surface extends axially to both sides to form opposing limiting blocks. The right side of the left clamp has a groove that matches the left limiting block of the winding clamp, and the left side of the right clamp has a groove that matches the right limiting block of the winding clamp.

[0021] The potting step includes: installing a left mold and a right mold on the outside of the prefabricated winding, and fastening the left mold, the prefabricated winding and the right mold together by a locking assembly, so that the prefabricated winding is located in the sealed cavity formed by the left mold and the right mold;

[0022] The potting compound is injected from the potting port of the sealed cavity. When the liquid level of the potting compound reaches the second preset height, the injection of the potting compound is stopped, and the locking assembly is opened to remove the left clamp and the right clamp, thereby obtaining an annular winding covered with a potting compound layer.

[0023] The right mold has a first receiving cavity, and the first receiving cavity has a groove that matches the right limiting block of the winding clamp; the left mold has a second receiving cavity, and the second receiving cavity has a groove that matches the left limiting block of the winding clamp; the first receiving cavity and the second receiving cavity cooperate to form a sealed cavity for accommodating the pre-made winding; the right mold or the left mold has a filling port;

[0024] A stator core is fabricated, and the required number of annular windings are sequentially fitted onto the stator core along the axial direction. The winding directions of any two adjacent annular windings are consistent, and every three adjacent annular windings are connected to the three-phase power supply A, B, and C respectively to form a winding unit.

[0025] Based on the above, each seat plate has two positioning surfaces on the side facing the stator along the stator's moving direction, and bolt holes are provided on the positioning surfaces, with adjacent seat plates being bolted together.

[0026] This invention has outstanding substantive features and significant progress compared to the prior art. Specifically,

[0027] In this invention, the toroidal winding has a winding clamp and a potting compound layer. The winding clamp plays a positioning role during the winding assembly process, thereby ensuring a uniform air gap between the toroidal winding and the mover magnet, which in turn ensures a uniform air gap between the stator and rotor of the motor, enabling the linear motor to operate well. The potting compound layer can be used for heat dissipation during motor operation and also serves as insulation, thus eliminating the need for the step of setting insulating paper for auxiliary insulation and the step of potting the entire motor after setting insulating paper during motor assembly. In addition, the winding clamp and potting compound layer can ensure the consistency of the toroidal winding specifications and improve the precision of the toroidal winding components.

[0028] In the winding step of the toroidal winding, the present invention utilizes the positioning function of the winding clamp to form a winding slot with the coil bearing surface of the left clamp, the right clamp and the winding clamp. The coil is wound on the coil bearing surface to fill the winding slot. This winding method can ensure the slot fill factor and the regularity of the main surface of the winding unit, thereby improving the winding quality.

[0029] In the potting step of the toroidal winding, this invention utilizes the positioning function of the winding clamp to securely connect the left mold, the toroidal winding, and the right mold, placing the toroidal winding within the sealed cavity formed by the left and right molds. Potting compound is injected through the potting port of the sealed cavity, and injection stops when the level of the potting compound reaches a second preset height. This potting method ensures consistent specifications for the toroidal windings, and the potting compound can both dissipate heat during motor operation and provide insulation.

[0030] In this embodiment, during the assembly process, there is no need to place insulating paper between the two annular windings. Instead, annular windings of the same specifications are directly assembled, which improves the accuracy of the entire assembly and ensures that the air gap between the annular windings and the magnet is uniform. This, in turn, ensures that the air gap between the stator and rotor of the motor is uniform, allowing the linear motor to operate well. Furthermore, there is no need to inject potting compound into the motor after assembly, simplifying the assembly steps.

[0031] In this invention, a linear silicon steel sheet structure is closely attached to each side of the stator core support frame, and several annular windings with the same winding direction are sequentially sleeved on the outside of the linear silicon steel sheet structure. The above structure makes the assembly of the linear motor stator structure simple, and each side of the annular winding is an effective side, resulting in small electromagnetic force pulsation.

[0032] The present invention provides mounting slots along the axial direction on each side of the stator core support frame. Several L-shaped silicon steel sheet structures are installed at equal intervals in each mounting slot according to a preset installation method. Each annular winding is installed in a winding positioning slot between two adjacent L-shaped silicon steel sheet structures. The above structure makes the linear motor stator structure compact, and each side of the annular winding is an effective side with a high electromagnetic force density. Attached Figure Description

[0033] Figure 1 This is a schematic diagram of the linear motor stator structure described in Embodiment 1.

[0034] Figure 2 This is a structural diagram of the support frame.

[0035] Figure 3 This is a schematic diagram of the toroidal winding distribution of the present invention.

[0036] Figure 4 This is a cross-sectional view of a toroidal winding.

[0037] Figure 5 It is a 3D diagram of a toroidal winding.

[0038] Figure 6 This is a schematic diagram of the winding clamp of the present invention.

[0039] Figure 7 This is a schematic diagram of the structure of the left clamp of the present invention.

[0040] Figure 8 This is a cross-sectional view of the left and right clamps and winding clamps of the present invention after assembly.

[0041] Figure 9 yes Figure 8 A magnified diagram of point I in the middle.

[0042] Figure 10 This is a perspective view of the fixture and winding clamp of the present invention after assembly.

[0043] Figure 11 This is a schematic diagram of the structure of the left mold of the present invention.

[0044] Figure 12 This is a schematic diagram of the structure of the right mold of the present invention.

[0045] Figure 13This is an assembly cross-sectional view of the right mold, left mold, and annular winding of the present invention.

[0046] Figure 14 This is a schematic diagram of the linear motor stator structure described in Embodiment 2.

[0047] Figure 15 This is a schematic diagram of the support frame described in Embodiment 2.

[0048] Figure 16 This is a schematic diagram of the linear motor stator structure described in Embodiment 3.

[0049] Figure 17 This is a structural diagram of the support frame.

[0050] Figure 18 This is a schematic diagram of a linear silicon steel sheet structure.

[0051] Figure 19 This is a schematic diagram of the linear motor stator structure described in Embodiment 4.

[0052] Figure 20 This is an exploded view of the installation of the stator core, L-shaped silicon steel sheet structure, and annular winding.

[0053] Figure 21 This is a schematic diagram of the linear motor in Example 5.

[0054] Figure 22 This is a schematic diagram of the moving part in Example 5.

[0055] In the diagram, 1. Winding clamp; 2. Boss; 3. Limiting block; 4. Left clamp; 5. Groove; 6. Threaded hole; 7. Right clamp; 8. Nut; 9. Bolt; 10. Prefabricated winding; 11. Left mold; 12. First receiving cavity; 13. Filling port; 14. Right mold; 15. Annular winding; 16. Filling adhesive layer; 17. Stator core; 18. Support frame; 19. L-shaped silicon steel sheet structure; 20. Lower base plate; 21. Right base plate; 22. Left base plate; 23. Upper base plate; 24. Magnet; 25. Straight silicon steel sheet structure; 26. Winding positioning groove; 27. Polygonal moving base. Detailed Implementation

[0056] The technical solution of the present invention will be further described in detail below through specific embodiments.

[0057] Example 1

[0058] This embodiment provides a linear motor stator structure, such as... Figure 1 As shown, it includes a stator core 17 and winding units; the stator core 17 includes a support frame 18 with a polygonal cross-section, preferably, as shown in the figure. Figure 2As shown, in this embodiment, a support frame 18 with a quadrilateral cross-section is selected; several annular windings with the same winding direction are sequentially sleeved on the support frame 18 along the axial direction; as shown Figure 3 As shown, every three adjacent toroidal windings are connected to the three-phase power supply A, B, and C respectively, forming a winding unit.

[0059] like Figure 4-6 As shown, the annular winding 15 includes a winding clamp 1, which is a polygonal structure. Each side of the polygonal structure is provided with a boss 2. The bosses 2 on multiple sides are connected to form a coil bearing surface. The bottom of the coil bearing surface extends axially to both sides to form opposing limiting blocks 3. A coil is wound on the coil bearing surface. The potting compound layer 16 is uniformly covered around the coil. The two sides of the potting compound layer 16 are vertically aligned with the two sides of the coil bearing surface.

[0060] It is understandable that any two adjacent ring windings can be spaced apart or placed close together, depending on the mover structure they are paired with.

[0061] Specifically, the assembly method of the linear motor stator structure includes the following steps:

[0062] Make several toroidal windings 15;

[0063] The manufacturing process of the annular winding 15 includes a winding step and a potting step;

[0064] The winding process includes: installing a left clamp 4 and a right clamp 7 on both sides of the winding clamp 1, and fastening them together with a locking assembly; the right side wall of the left clamp 4, the left side wall of the right clamp 7, and the coil bearing surface of the winding clamp 1 form a winding groove; winding the coil onto the coil bearing surface to fill the winding groove until the height of the coil in the winding groove reaches a first preset height, stopping the winding, opening the locking assembly, and removing the left clamp 4 and the right clamp 7 to obtain the pre-made winding 10;

[0065] Among them, such as Figure 7 As shown, the right side of the left clamp 4 is provided with a groove 5 that matches the left limiting block 3 of the winding clamp 1;

[0066] It is understood that the left side of the right clamp 7 is provided with a groove 5 that matches the right limiting block 3 of the winding clamp 1, and the specific structure is the same as... Figure 7 similar;

[0067] Furthermore, in specific implementation, the locking assembly includes a bolt 9 and a nut 8; correspondingly, the winding clamp 1, the left clamp 4, and the right clamp 7 are all provided with threaded holes 6. The bolt is passed through the threaded holes 6 and cooperates with the nut 8 to assemble the winding clamp 1, the left clamp 4, and the right clamp 7 together.

[0068] Specifically, the structural diagram of the assembled winding clamp 1, the left clamp 4, and the right clamp 7 is as follows: Figure 8-10 As shown, the winding clamp 1, the left clamp 4 and the right clamp 7 are fastened together to form a winding groove. The setting of the winding groove makes the coil winding arrangement more regular and dense, improving the slot fill factor. Moreover, since the winding groove formed before each winding is of the same size, it can ensure that the specifications of the formed annular winding are consistent and meet the winding quality, thus improving the stability of the winding quality.

[0069] After obtaining the pre-made winding 10, a potting compound layer 16 needs to be added to the outside of the pre-made winding 10. Specifically, the potting step includes: installing a left mold 11 and a right mold 14 on the outside of the pre-made winding 10 formed in the winding step, and fastening them together with a locking assembly, wherein the left mold 11 and the right mold 14 form a sealed cavity; injecting potting compound into the sealed cavity from the potting port 13, preferably, the potting compound is epoxy resin glue; when the liquid level of the potting compound in the sealed cavity reaches a second preset height, stopping the injection of the potting compound, opening the locking assembly, and disassembling the left clamp 4 and the right clamp 7, thereby obtaining an annular winding 15 covered with the potting compound layer 16.

[0070] The right mold 14 has a first receiving cavity 12, and the first receiving cavity 12 has a groove 5 that matches the right limiting block 3 of the winding clamp 1; the left mold 11 has a second receiving cavity, and the second receiving cavity has a groove 5 that matches the left limiting block 3 of the winding clamp 1; the first receiving cavity 12 and the second receiving cavity cooperate to form a sealed cavity for accommodating the pre-made winding; the right mold 14 or the left mold 11 has a filling port 13.

[0071] In practical implementation, the sizes of the first receiving cavity 12 and the second receiving cavity can be set according to requirements, such as... Figure 11 and Figure 12The diagram shows a specific embodiment of the left mold 11 and the right mold 14. In this embodiment, the first receiving cavity 12 of the right mold 14 is much larger than the second receiving cavity of the left mold 11. During assembly, the pre-made winding 10 is first installed in the first receiving cavity 12 of the right mold 14, then the groove 5 of the left mold 11 is engaged with the left limiting block 3 of the winding clamp 1, and finally the locking assembly is used to fasten the left mold 11, the winding clamp 1, and the right mold 14.

[0072] In practical implementation, the locking assembly includes a bolt 9 and a nut 8; both the left mold 11 and the right mold 14 are provided with corresponding threaded holes 6. The bolt 9 is passed through the threaded holes 6 and cooperates with the nut 8 to assemble the prefabricated winding 10, the left mold 11, and the right mold 14 together. Specifically, the structural diagram of the prefabricated winding 10, the left mold 11, and the right mold 14 after assembly is shown in the figure below. Figure 13 As shown.

[0073] The winding clamp 1, the left mold 11, and the right mold 14 are fastened together to form a potting groove. Epoxy resin glue is injected into the potting groove through the potting port 13, thereby forming an insulating structure—the potting glue layer 16—on the outside of the prefabricated winding 10. The potting glue layer 16 can eliminate the need to place additional insulating paper between adjacent annular windings 15 for auxiliary insulation during the later assembly of the linear motor. At the same time, the potting glue layer 16 also has a heat dissipation function, which can reduce the need to fill the linear motor with sealant for heat dissipation after inserting interphase insulating paper.

[0074] Fabricate a stator core 17, and sequentially install the required number of annular windings 15 on the stator core 17 along the axial direction;

[0075] The specific steps are as follows:

[0076] A support frame 18 with a polygonal cross-section is obtained; preferably, the support frame is an aluminum support.

[0077] The required number of annular windings 15 are sequentially mounted on the support frame 18 in the same winding direction;

[0078] Each three adjacent toroidal windings 15 are connected to the three-phase power supply A, B, and C respectively to form a winding unit.

[0079] It is understandable that, depending on the performance requirements of the motor, the winding clamp 1 can be made of magnetic or non-magnetic material. When the winding clamp 1 is made of magnetic material, the motor thrust fluctuation is small.

[0080] In this embodiment, during the winding step, the positioning function of the winding clamp 1 is used to make the left clamp 4, the right clamp 7 and the coil bearing surface of the winding clamp 1 form a winding groove. The coil is wound on the coil bearing surface to fill the winding groove. This winding method can ensure the slot fill factor and the regularity of the main surface of the annular winding 15, and improve the winding quality.

[0081] In this embodiment, during the potting step, the positioning function of the winding clamp 1 is used to securely connect the left mold 11, the pre-made winding 10, and the right mold 14, so that the pre-made winding 10 is located in the sealed cavity formed by the left mold 11 and the right mold 14. Epoxy resin adhesive is injected from the potting port 13 of the sealed cavity, and the injection of epoxy resin adhesive is stopped when the liquid level of the epoxy resin adhesive reaches a second preset height. This potting method ensures that the specifications of the annular winding 15 are consistent, and the epoxy resin adhesive of the annular winding 15 can both dissipate heat during motor operation and provide insulation.

[0082] In this embodiment, during the assembly process, there is no need to place insulating paper between the two sealed cavity annular windings 15. Instead, the sealed cavity annular windings 15 of the same specifications are directly fitted together, which improves the accuracy of the entire assembly and simplifies the assembly steps. Furthermore, after the fitting is completed, there is no need to fill the motor with epoxy resin glue, which further simplifies the assembly steps.

[0083] Example 2

[0084] The difference between this embodiment and Embodiment 1 is that: Figure 14-15 As shown, each side of the support frame 18 is provided with a plurality of winding positioning grooves 26 perpendicular to the axial direction, and each winding positioning groove 26 is equipped with a ring winding 15.

[0085] Preferably, each of the winding positioning slots 26 has a limiting slot on each of its top two sides corresponding to the limiting block 3 of the winding clamp 1. The setting of the limiting slot is conducive to the precise assembly of the annular winding 15.

[0086] Correspondingly, in the assembly method of the linear motor stator structure, the specific steps for fabricating the stator core 17 and sequentially mounting the required number of annular windings 15 on the stator core 17 along the axial direction are as follows:

[0087] Obtain a support frame 18 with a polygonal cross-section, and open a corresponding number of winding positioning slots 26 perpendicular to the axial direction on each side of the support frame 18 according to the required number of annular windings.

[0088] And a ring winding 15 is installed in each winding positioning slot 26.

[0089] Example 3

[0090] The difference between this embodiment and Embodiment 1 is that: Figure 16-18 As shown, each side of the support frame 18 is provided with an axial through groove, and a straight silicon steel sheet structure 25 is installed in the mounting through groove. The straight silicon steel sheet structure 25 is made of multiple straight silicon steel sheets stacked together. The support frame 18 is provided with the required number of annular windings 15 in sequence along the axial direction, and each annular winding 15 is tightly attached to the straight silicon steel sheet structure 25 on each side of the support frame 18.

[0091] Correspondingly, in the assembly method of the linear motor stator structure, the specific steps for fabricating the stator core 17 and sequentially mounting the required number of annular windings 15 on the stator core 17 along the axial direction are as follows:

[0092] A support frame 18 with a polygonal cross-section is obtained, and an mounting through slot is opened on each side of the support frame 18 along the axial direction. Preferably, the support frame is an aluminum support.

[0093] Multiple straight silicon steel sheets are stacked to form a straight silicon steel sheet structure 25, and one of the straight silicon steel sheet structures 25 is installed in the mounting slot on each side of the support frame 18.

[0094] The required number of annular windings 15 are sequentially mounted on the support frame 18 in the same winding direction, with each annular winding 15 being tightly attached to the straight silicon steel sheet structure 25 on each side of the support frame 18.

[0095] It is understood that in this embodiment, the linear motor stator structure is simple to assemble, and each side of the annular winding 15 is an effective side, resulting in small electromagnetic force pulsation. The disadvantage is that the power density is low.

[0096] Example 4

[0097] The difference between this embodiment and embodiment 3 is that: Figure 19-20 As shown, several L-shaped silicon steel sheet structures 19 are installed at equal intervals in the mounting slots on each side of the support frame 18 according to a preset installation method. A winding positioning slot is formed between two adjacent L-shaped silicon steel sheet structures 19. An annular winding 15 is installed in each winding positioning slot. The winding direction of all annular windings 15 is the same.

[0098] The L-shaped silicon steel sheet structure 19 is made of multiple L-shaped silicon steel sheets stacked together, and the L-shaped silicon steel sheet structure 19 is connected to the mounting through slot with an interference fit, thereby resisting the magnetic attraction of the mover structure to the stator.

[0099] Preferably, each of the winding positioning slots 26 has a limiting slot on each of its top two sides corresponding to the limiting block 3 of the winding clamp 1. The setting of the limiting slot is conducive to the precise assembly of the annular winding 15.

[0100] Correspondingly, in the assembly method of the linear motor stator structure, the specific steps for fabricating the stator core 17 and sequentially mounting the required number of annular windings 15 on the stator core 17 along the axial direction are as follows:

[0101] Obtain a support frame 18 with a polygonal cross-section, and open mounting slots along the axial direction on each side of the support frame 18;

[0102] Multiple L-shaped silicon steel sheets are stacked to form an L-shaped silicon steel sheet structure 19, wherein each L-shaped silicon steel sheet has a limiting groove on both sides of the top of the vertical side corresponding to the limiting block of the winding clamp 1.

[0103] A set of L-shaped silicon steel sheet structures 19 are installed in the mounting slots on each side of the support frame 18, and then an annular winding 15 is pushed in from the other end of the support frame 18; then the installation of the next set of L-shaped silicon steel sheet structures 19 and the next annular winding 15 is carried out in sequence until the number of annular windings 15 reaches the required number of windings; it should be noted that the winding direction of any two adjacent annular windings 15 is the same.

[0104] It is understood that in this embodiment, the linear motor stator structure is compact, and each side of the annular winding 15 is an effective side, resulting in a high electromagnetic force density.

[0105] Example 5

[0106] This embodiment provides a linear motor, including a stator structure and a mover structure, such as... Figure 21 As shown, the stator structure is the linear motor stator structure described in any one of Embodiments 1-4, and the mover structure includes a polygonal mover base 27 composed of multiple base plates, with magnets 24 evenly distributed on the side of each base plate facing the stator in accordance with the magnetic pole direction.

[0107] like Figure 22 As shown, in this embodiment, the moving part structure is a quadrilateral moving part base. The moving part base includes a lower base plate 20, a right base plate 21, a left base plate 22, an upper base plate 23, and a magnet 24. The magnet 24 is evenly distributed on the lower base plate 20, the right base plate 21, the left base plate 22, and the upper base plate 23 according to the magnetic pole direction.

[0108] In specific implementation, the lower base plate 20, the right base plate 21, the left base plate 22 and the upper base plate 23 are provided with protrusions on the side facing the stator, and the magnets 24 are evenly attached to the protrusions of the lower base plate 20, the right base plate 21, the left base plate 22 and the upper base plate 23 in accordance with the magnetic pole direction.

[0109] Preferably, the magnets 24 on the upper seat plate 23, the lower seat plate 20, the left seat plate 22, and the right seat plate 21 are all magnetized along the normal direction, and the magnetization directions of adjacent magnets 24 are opposite; and the magnetization directions of the magnets 24 on the lower seat plate 20 and the upper seat plate 23 are opposite, and the magnetization directions of the magnets 24 on the left seat plate 22 and the right seat plate 21 are opposite.

[0110] The lower base plate 20, the right base plate 21, the left base plate 22, and the upper base plate 23 are each provided with two positioning surfaces along the stator moving direction on the side facing the stator. Bolt holes are provided on the positioning surfaces. The lower end faces of the right base plate 21 and the left base plate 22 are fixed to the positioning surfaces on both sides of the lower base plate 20 by nuts 8 and bolts 9 to ensure that the left and right magnets 24 are symmetrical. The positioning surface of the upper base plate 23 is close to the left base plate 22, and the lower end faces of the upper base plate 23 are fastened to the upper end faces of the right base plate 21 and the left base plate 22 by nuts 8 and bolts 9.

[0111] It is understood that the magnet 24 can also be fixed to the lower base plate 20, the right base plate 21, the left base plate 22 and the upper base plate 23 in other ways.

[0112] It is understood that, in this embodiment, the magnet 24 is mounted on the mover and the annular winding 15 is mounted on the stator, therefore the linear motor in this embodiment is an internal winding type.

[0113] It is understood that the moving part structure may also include a U-shaped base and a top cover plate, and the magnet 24 is evenly pasted onto the inner wall of the U-shaped base and the top cover plate in accordance with the magnetic pole direction.

[0114] Furthermore, all the moving parts are supported by silicon steel sheets with magnetic conductivity; all the magnets 24 are made of permanent magnet materials such as rubidium iron boron, samarium cobalt, and ferrite.

[0115] Permanent magnet linear motors, with their high power density, have become a hot topic in current motor technology research. Structurally, permanent magnet linear motors are divided into flat and cylindrical types. Cylindrical permanent magnet linear motors have high thrust (power) density, offering significant advantages in motor driving performance. However, due to limitations in the processing technology of hard and brittle magnet materials, their manufacturing is difficult. Compared to cylindrical permanent magnet linear motors, flat permanent magnet linear motors are easier to manufacture, but they are mostly single-sided or double-sided, with the windings on other sides not being utilized. This results in a significantly reduced driving force compared to cylindrical permanent magnet linear motors of the same stroke, failing to fully realize the high thrust (power) density advantage of permanent magnet linear motors. In this embodiment, the air gap cross-section formed by the magnet 24 in the linear motor's mover structure and the annular winding 15 in the stator is a rectangular structure, enabling direct linear motion of the load. It offers advantages such as high thrust density, high power density, low thrust fluctuation, and ease of processing and assembly.

[0116] In this embodiment, since the primary winding adopts the annular winding 15, the length of the end winding is effectively reduced, the end copper loss is reduced, and the motor efficiency is improved.

[0117] In addition, the annular winding 15 in this embodiment has a winding clamp 1 and a potting compound layer 16. The setting of the winding clamp 1 and the potting compound layer 16 can ensure that the specifications of the annular winding are consistent, improve the component accuracy of the annular winding 1 and improve the accuracy of the entire assembly, ensure that the air gap between the annular winding 1 and the magnet 24 is uniform, thereby ensuring that the air gap between the stator and rotor of the motor is uniform, so that the linear motor can operate well.

[0118] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them; although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications can still be made to the specific implementation of the present invention or equivalent substitutions can be made to some technical features without departing from the spirit of the technical solutions of the present invention, and all such modifications and substitutions should be covered within the scope of the technical solutions claimed in the present invention.

Claims

1. A stator structure for a linear motor, comprising a stator core, characterized in that: The stator core includes a support frame with a polygonal cross-section; several annular windings with the same winding direction are sequentially sleeved on the stator core along the axial direction, and every three adjacent annular windings are respectively connected to the three-phase power supply A, B, and C to form a winding unit. Each annular winding includes a winding clamp, which is a polygonal structure with the same number of sides as the support frame. Each side of the polygonal structure is provided with a boss, and the bosses on multiple sides are connected to form a coil bearing surface. The bottom of the coil bearing surface extends axially to both sides to form opposing limiting blocks. A coil is wound on the coil bearing surface, and a potting compound is uniformly applied around the coil. The two edges of the potting compound are vertically aligned with the two sides of the coil bearing surface. The manufacturing process of the toroidal winding includes a winding step and a potting step; The winding step includes: installing a left clamp and a right clamp on both sides of the winding clamp respectively, and fastening the left clamp, the winding clamp and the right clamp together by a locking assembly, so that the right side wall of the left clamp, the left side wall of the right clamp and the coil bearing surface of the winding clamp form a winding groove. The coil is wound on the coil bearing surface to fill the winding groove until the height of the coil in the winding groove reaches the first preset height. Then the winding is stopped, and the locking assembly is opened to remove the left clamp and the right clamp to obtain the pre-made winding. The left clamp has a groove on its right side that matches the left limiting block of the winding clamp, and the right clamp has a groove on its left side that matches the right limiting block of the winding clamp. The potting step includes: installing a left mold and a right mold on the outside of the prefabricated winding respectively, and fastening the left mold, the prefabricated winding and the right mold together by a locking assembly, so that the prefabricated winding is located in the sealed cavity formed by the left mold and the right mold; The potting compound is injected from the potting port of the sealed cavity. When the liquid level of the potting compound reaches the second preset height, the injection of potting compound is stopped, and the locking assembly is opened to remove the left clamp and the right clamp, thereby obtaining an annular winding covered with a potting compound layer. The right mold has a first receiving cavity, and the first receiving cavity has a groove that matches the right limiting block of the winding clamp; the left mold has a second receiving cavity, and the second receiving cavity has a groove that matches the left limiting block of the winding clamp; the first receiving cavity and the second receiving cavity cooperate to form a sealed cavity for accommodating the pre-made winding; the right mold or the left mold has a filling port.

2. The linear motor stator structure according to claim 1, characterized in that: The support frame has several winding positioning slots perpendicular to the axial direction on each side, and each winding positioning slot contains one of the annular windings.

3. The linear motor stator structure according to claim 1, characterized in that: Each side of the support frame is provided with an axial mounting slot, and a straight silicon steel sheet structure is installed in the mounting slot. The straight silicon steel sheet structure is made of multiple straight silicon steel sheets stacked together. The support frame is provided with the required number of annular windings in the same winding direction, and each annular winding is tightly attached to the straight silicon steel sheet structure on each side of the support frame.

4. The linear motor stator structure according to claim 1, characterized in that: Each side of the support frame is provided with an axial mounting slot. Several L-shaped silicon steel sheet structures are installed at equal intervals in each mounting slot according to a preset installation method. A winding positioning slot is formed between two adjacent L-shaped silicon steel sheet structures. One of the annular windings is installed in each winding positioning slot. The L-shaped silicon steel sheet structure is made of multiple L-shaped silicon steel sheets stacked together, and the L-shaped silicon steel sheet structure is interference-fitted with the mounting slot.

5. An assembly method for a linear motor stator structure, characterized in that, Includes the following steps: The manufacturing process of the toroidal winding includes a winding step and a potting step. The winding step includes: installing a left clamp and a right clamp on both sides of the winding clamp respectively, and fastening the left clamp, the winding clamp and the right clamp together by a locking assembly, so that the right side wall of the left clamp, the left side wall of the right clamp and the coil bearing surface of the winding clamp form a winding groove. The coil is wound on the coil bearing surface to fill the winding groove until the height of the coil in the winding groove reaches the first preset height. Then the winding is stopped, and the locking assembly is opened to remove the left clamp and the right clamp to obtain the pre-made winding. The winding clamp is a polygonal structure with the same number of sides as the support frame. Each side of the polygonal structure has a boss, and the bosses on multiple sides are connected to form a coil bearing surface. The bottom of the coil bearing surface extends axially to both sides to form opposing limiting blocks. The right side of the left clamp has a groove that matches the left limiting block of the winding clamp, and the left side of the right clamp has a groove that matches the right limiting block of the winding clamp. The support frame is a support frame with a polygonal cross-section. The potting step includes: installing a left mold and a right mold on the outside of the prefabricated winding, and fastening the left mold, the prefabricated winding and the right mold together by a locking assembly, so that the prefabricated winding is located in the sealed cavity formed by the left mold and the right mold; The potting compound is injected from the potting port of the sealed cavity. When the liquid level of the potting compound reaches the second preset height, the injection of potting compound is stopped, and the locking assembly is opened to remove the left clamp and the right clamp, thereby obtaining an annular winding covered with a potting compound layer. The right mold has a first receiving cavity, and the first receiving cavity has a groove that matches the right limiting block of the winding clamp; the left mold has a second receiving cavity, and the second receiving cavity has a groove that matches the left limiting block of the winding clamp; the first receiving cavity and the second receiving cavity cooperate to form a sealed cavity for accommodating the pre-made winding; the right mold or the left mold has a filling port; A stator core is fabricated, and the required number of annular windings are sequentially fitted onto the stator core along the axial direction. The winding directions of any two adjacent annular windings are consistent, and every three adjacent annular windings are connected to the three-phase power supply A, B, and C respectively to form a winding unit.

6. The assembly method of a linear motor stator structure according to claim 5, characterized in that, The steps of fabricating a stator core and sequentially mounting the required number of annular windings on the stator core along the axial direction include: Obtain a support frame with a polygonal cross-section, and open a corresponding number of winding positioning slots perpendicular to the axial direction on each side of the support frame according to the required number of annular windings. And one of the aforementioned annular windings is installed in each winding positioning slot.

7. The assembly method of a linear motor stator structure according to claim 5, characterized in that, The steps of fabricating a stator core and sequentially mounting the required number of annular windings on the stator core along the axial direction include: Obtain a support frame with a polygonal cross-section, and open mounting slots along the axial direction on each side of the support frame; Multiple straight silicon steel sheets are stacked to form a straight silicon steel sheet structure, and one of the straight silicon steel sheet structures is installed in the mounting slot on each side of the support frame. The required number of annular windings are sequentially mounted on the support frame in the same winding direction, with each annular winding tightly attached to a straight silicon steel sheet structure on each side of the support frame.

8. The assembly method of a linear motor stator structure according to claim 5, characterized in that, The steps of fabricating a stator core and sequentially mounting the required number of annular windings on the stator core along the axial direction include: Obtain a support frame with a polygonal cross-section, and open mounting slots along the axial direction on each side of the support frame; Multiple L-shaped silicon steel sheets are stacked to form an L-shaped silicon steel sheet structure, wherein limit grooves are respectively opened on the top two sides of the vertical side of each L-shaped silicon steel sheet corresponding to the limit block of the winding clamp; A set of L-shaped silicon steel sheet structures is installed in the mounting slots on each side of the support frame, and then an annular winding is pushed in from the other end of the support frame; the installation of the next set of L-shaped silicon steel sheet structures and the next annular winding is repeated in sequence until the number of annular windings reaches the required number of windings.

9. A linear motor, characterized in that: It includes a stator and a mover. The stator is the linear motor stator structure according to any one of claims 1-4. The mover includes a polygonal mover base composed of multiple base plates. Each base plate has magnets evenly distributed in the direction of magnetic poles on the side facing the stator.

10. The linear motor according to claim 9, characterized in that: Each seat plate has two positioning surfaces on the side facing the stator along the stator's moving direction. Bolt holes are provided on the positioning surfaces, and adjacent seat plates are bolted together.

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