Coreless linear motor coil and winding based on additive manufacturing technology and motor

Abstract

The application provides a coreless linear motor coil and winding and motor based on additive manufacturing technology, and belongs to the technical field of motors. The coil is made of additive manufacturing wire, the wire is sequentially connected by a plurality of left and right wires, the left and right wires are of the same structure and are in strip structure; the upper and lower ends of the wire are all at an angle of α with the effective edge; the effective edges of the left and right wires are parallel to each other and have equal lengths; the total width of each effective edge of the left wire and each effective edge of the right wire is t / 3, and the distance between the two is t , t is the motor pole pitch. The application improves the coil magnetic flux, improves the winding factor, reduces the end volume, thereby increasing the thrust density of the motor; at the same time, the multi-layer strip conductor arrangement is adopted, the eddy current loss is reduced, the eddy current braking force is reduced, and the dynamic performance and output thrust of the motor are improved.

Description

Technical Field

[0001] This invention belongs to the field of motor technology, and specifically relates to a coreless linear motor coil based on additive manufacturing technology, as well as a coreless linear motor winding and a coreless linear motor based on the coil. Background Technology

[0002] One of the key components of an electric motor is the winding, which is not only responsible for generating the magnetic field that controls motion, but also generates losses that directly affect the motor's efficiency and temperature rise, especially in coreless linear motors. Coreless linear motor windings generally have two structures: a concentrated winding structure and a distributed winding structure.

[0003] Centralized winding structures are simple in structure and easy to manufacture and maintain. However, this structure results in a lower winding factor and higher harmonic order, directly weakening the motor's output performance and easily generating local hot spots. Therefore, to further improve the motor's thrust, a distributed winding structure is often used. However, distributed winding structures have longer ends and higher resistance, increasing winding losses. Existing distributed winding structures for coreless linear motors result in hollow coils at both ends of the winding, leading to low utilization of the air gap space. At the same time, the limited air gap space in coreless linear motors places higher demands on the connection and volume of the distributed winding ends, increasing the difficulty of design and winding.

[0004] Currently, additive manufacturing technology is being used to produce motor windings, enabling more complex structural topologies to overcome the shortcomings of traditional winding structures, such as limited spatial freedom and simplistic forms. However, coreless linear motors have a double-sided secondary structure, and the multi-layered, wide conductor windings produced by additive manufacturing technology induce significant eddy currents, increasing winding losses and the risk of motor overheating. Simultaneously, the interaction between eddy currents and the secondary magnetic field generates reverse eddy current braking forces, further limiting the motor's dynamic performance. Therefore, a rational winding structure topology design is essential. Summary of the Invention

[0005] To address the shortcomings of the aforementioned winding structure, this invention proposes a coreless linear motor coil based on additive manufacturing technology. By using left and right conductors and a triangular connection at the end of the coil, the end volume and coil loss are reduced, while the air gap space utilization and the thrust density of the motor are improved.

[0006] The present invention also provides a winding for a coreless linear motor coil using the above-described additive manufacturing technology.

[0007] The present invention also provides a motor employing the above-mentioned coreless linear motor winding based on additive manufacturing technology.

[0008] The specific technical solution of the present invention is as follows:

[0009] This invention provides a coreless linear motor coil based on additive manufacturing technology. The coil is made of additively manufactured wire, which is composed of several left and right wires connected sequentially. The left and right wires have identical structures, each including an effective side and an end. The end is located on both sides of each effective side, divided into an upper end and a lower end. Both the effective side and the end are strip-shaped, with the upper and lower ends forming an angle α with the effective side. The effective sides of the left and right wires are parallel and of equal length. The total width of all effective sides of the left and right wires is [missing information]. / 3, the distance between the two is , This refers to the motor pole pitch.

[0010] Furthermore, the wires in the coil are connected by connecting the upper end of the first left wire to the upper end of the first right wire, then connecting the lower end of the first right wire to the lower end of the second left wire, and connecting the upper end of the second left wire to the upper end of the second right wire, and so on, in series to form a single wire. All the coil terminals are located on the outermost layer of the coil.

[0011] Furthermore, the effective side length of the conductor is L, corresponding to the axial length of the motor's permanent magnet; the connected left and right conductors are spatially misaligned by a distance C. i This distance is generally determined by additive manufacturing technology and insulation processes; the distance between adjacent upper / lower ends of the left / right conductor is C. es (Generally twice the insulation thickness after coil insulation treatment, with appropriate margin allowed); the distance between adjacent effective sides of the left / right conductor is C. s Satisfying C s =C es / sinα; The width of the effective side in the left / right duct is C w Thickness C t The number of left-hand wires / right-hand wires is N, satisfying N = [ / 3(C w +C s [], (the symbol [] indicates rounding); the width of the upper / lower ends of the left / right conductor is C. we Satisfying C we =C w sinα.

[0012] Furthermore, the angle α between the upper and lower ends and the effective side satisfies: Where p is the number of poles of the motor, and Z is the number of slots of the coreless linear motor with concentrated windings.

[0013] Furthermore, the distance between each turn of the conductor is 180° electrical degrees, and the coil pitch factor k cp =1, the distribution factor of the coil is n is the harmonic order.

[0014] This invention provides a coreless linear motor winding based on additive manufacturing technology, which is made of coreless linear motor coils based on additive manufacturing technology. Each phase winding has at least one coil, and the coils of each phase winding are arranged horizontally at 60° electrical angle intervals. The coils are connected in series, in parallel, or in series-parallel according to the winding phase sequence.

[0015] Furthermore, the winding phase sequence is arranged according to the AZBXCY array; the number of windings per pole per phase is 1, the winding distribution factor is 1, and the winding factor is [missing information]. Among them, C s C is the distance between adjacent valid edges of the left / right traverse. w The width of the effective side of the left / right conductor. Where N is the pole pitch of the motor, N is the number of left / right conductors, and n is the harmonic order.

[0016] This invention provides a coreless linear motor based on additive manufacturing technology, which is made using the aforementioned coreless linear motor windings based on additive manufacturing technology.

[0017] The present invention has the following advantages over the prior art:

[0018] 1. This invention relates to a coreless linear motor coil based on additive manufacturing technology. The effective side of the coil conductor is a strip structure. Compared with existing multi-layer flat and wide conductors, the area cut by the effective side of the coil conductor and the air gap magnetic field is greatly reduced, which suppresses the formation of eddy currents inside the coil and reduces winding eddy current losses. Furthermore, the reverse eddy current braking force of the interaction between the eddy current and the air gap magnetic field is also greatly reduced, improving the dynamic performance and output thrust of the motor.

[0019] 2. By rationally designing the angle between the end of the coil conductor and the effective side, this invention effectively reduces the length of the end of the coil conductor while increasing the output thrust of the motor. Compared with traditional enameled round wire windings, the axial length of the primary winding is reduced, further improving the thrust density of the motor.

[0020] 3. The coil conductor routing of this invention is similar to that of conventional winding with the coil placed vertically. On the one hand, this ensures that all coil terminals are located on the outside, avoiding the situation where the terminals are located inside the coil and cannot be connected externally as in conventional wiring. On the other hand, it reduces the complexity of the winding structure, increases the elasticity of the coil, and is beneficial for subsequent coil surface polishing and insulation treatment.

[0021] 4. The coreless linear motor winding of the present invention, based on additive manufacturing technology, adopts a distributed structure and the effective area of ​​the winding coupled with the permanent magnet is rectangular. Compared with the existing additive manufacturing rhombic winding and the traditional centralized enameled round wire winding, it increases the winding turn flux and improves the motor output thrust.

[0022] 5. The present invention is a coreless linear motor based on additive manufacturing technology. By adopting a rationally designed coil structure and winding structure, the dynamic performance and output thrust of the motor are improved. Attached Figure Description

[0023] Figure 1 This is a top view of the coil of the present invention;

[0024] Figure 2 for Figure 1 The left view;

[0025] Figure 3 This is a schematic diagram of the main structural parameters of the coil of the present invention;

[0026] Figure 4 This is a schematic diagram of the three-dimensional structure of the coil of the present invention;

[0027] Figure 5 This is a schematic diagram showing the extension of the coil conductor end of the present invention;

[0028] Figure 6 This is another structural form of the coil of the present invention;

[0029] Figure 7 This is a schematic diagram of the coreless linear motor winding based on additive manufacturing technology according to the present invention;

[0030] Figure 8 This is a schematic diagram of the coreless linear motor based on additive manufacturing technology of the present invention;

[0031] Figure 9 This is a schematic diagram of an existing multilayer flat wide conductor winding based on additive manufacturing technology;

[0032] Figure 10 Eddy current loss curves for coreless linear motors with different winding structures under the same load conditions;

[0033] Figure 11 The output thrust curves of coreless linear motors with different winding structures under the same load conditions are shown.

[0034] In the diagram, 1: effective side of the left conductor; 2: effective side of the right conductor; 3: upper end of the left conductor; 3-1 to 3-N: represent the upper ends of the 1st to Nth left conductors respectively; 4: upper end of the right conductor; 4-1 to 4-N: represent the upper ends of the 1st to Nth right conductors respectively; 5: lower end of the left conductor; 5-1 to 5-N: represent the lower ends of the 1st to Nth left conductors respectively; 6: lower end of the right conductor; 6-1 to 6-N: represent the lower ends of the 1st to Nth right conductors respectively; 7: coil terminal; 8: conductor end extension; 9: primary winding; 10: secondary back yoke; 11: permanent magnet.

[0035] Parameter descriptions: L: Effective side length of the coil; C i : The misalignment distance between connected left and right conductors; C t : Wire thickness; C w : Width of the effective side of the left / right conductor; C s : Distance between adjacent valid sides of the left / right traverse; C es : Distance between adjacent upper / lower ends of the left / right conductor; C we : Width of the upper / lower ends of the left / right conductor; α: Angle between the upper / lower ends and the effective side; Pole pitch of a coreless linear motor. Detailed Implementation

[0036] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0037] Example 1:

[0038] like Figure 1 As shown, this invention relates to a coreless linear motor coil based on additive manufacturing technology. The coil is made of additively manufactured wire, which is composed of several left and right wires connected sequentially. The left and right wires have identical structures, each including an effective side and an end. The end is located on both sides of each effective side, divided into an upper end and a lower end. Both the effective side and the end are strip-shaped, with the upper and lower ends forming an angle α with the effective side. The effective sides of the left and right wires are parallel and of equal length. The total width of all effective sides of the left and right wires is [missing information]. / 3, the distance between the two is , This refers to the motor pole pitch.

[0039] like Figure 1 As shown, the left conductor includes: the effective side 1 of the left conductor, the upper end 4 of the left conductor, and the lower end 5 of the left conductor; the right conductor includes: the effective side 2 of the right conductor, the upper end 3 of the right conductor, and the lower end 6 of the right conductor. Figure 2 As shown, the thickness of the conductors is C. t That is, the effective sides of the upper and lower conductors and the thickness of the upper and lower ends are equal.

[0040] Furthermore, such as Figure 1 , Figure 3 , Figure 4As shown, the wires in the coil are connected by connecting the upper end 3-1 of the first left wire to the upper end 4-1 of the first right wire, then connecting the lower end 6-1 of the first right wire to the lower end 5-2 of the second left wire, and the upper end 3-2 of the second left wire to the upper end 4-2 of the second right wire, and so on, in series to form a single wire. The coil terminals 7 are all located on the outermost layer of the coil. Generally, the lengths of the left and right wire ends only need to ensure mutual coupling, but the wire ends can also be appropriately extended, such as forming a wire end extension 8 on the left wire, which connects to the right wire. Figure 5 As shown, the coil strength and heat transfer capacity are also enhanced at this time.

[0041] The dimensions of the coil include: the length L of the effective side of the conductor, and the misalignment distance C between the connected left and right conductors. i Distance C between adjacent upper and lower ends of the left / right conductor es Distance C between adjacent effective sides of the left / right traverse s Width C of the effective side of the left / right conductor w , conductor thickness C t Number of left / right conductors N, width of upper / lower end C we And the angle α between the upper and lower ends of the conductor and the effective side. The effective side length L of the coil is consistent with the axial length of the permanent magnet of the motor, ensuring the maximum effective coupling area between the coil and the permanent magnet; C i Generally determined by additive manufacturing technology and insulation processes, smaller values ​​generally result in better motor output performance. The coil parameter determination process is as follows: First, determine the distance C between the adjacent upper / lower ends of the left / right conductor. es Generally, it should be twice the insulation thickness after coil insulation treatment, with appropriate margin allowed; then the width C of the effective side of the left / right conductor. w , conductor thickness C t The angle α between the upper and lower ends of the conductor and the effective side can be selected based on the motor output thrust, eddy current loss, and motor constant; when calculating the motor output thrust, eddy current loss, and motor constant, the distance C between adjacent effective sides of the left / right conductor is... s According to relation C s =C es / sinα is determined, and the number of left and right conductors N is determined according to the formula N = [ / 3(C w +C s [ ] Determine, (the symbol [ ] indicates rounding), the width C of the wire end. we According to relation C we =C w sinα is determined. The angle α between the upper and lower ends and the effective side satisfies... Where p is the number of poles of the motor, and Z is the number of slots of the coreless linear motor with concentrated windings.

[0042] In this coil structure, the distance between each turn of the conductor is 180 electrical degrees, and the coil pitch factor k cp =1, the distribution factor of the coil is n is the harmonic order.

[0043] Example 2:

[0044] like Figure 6 As shown, this embodiment provides another structural form of the coreless linear motor coil based on additive manufacturing technology, namely, the left and right conductors are misaligned in space with... Figure 4 The difference is that the structural parameters of the coil and the arrangement of the wires remain the same, as in Example 1.

[0045] Example 3:

[0046] like Figure 7 As shown, this example provides the winding of a coreless linear motor coil based on additive manufacturing technology in Embodiment 1. The 21 coils are arranged in an alternating layered configuration, with each phase winding containing 7 coils. The coils of each phase winding are arranged at 60° electrical angle intervals to form the three-phase winding of the coreless linear motor, which is a distributed structure. Each coil terminal 7 is located on the outermost layer and connected in series, parallel, or series-parallel according to the winding phase sequence, which is arranged in an AZBXCY array. Since there is one winding per pole per phase, the distribution factor of the winding is also 1, and the winding factor is [missing value]. n is the harmonic order.

[0047] Example 4:

[0048] like Figure 8 As shown, this embodiment provides a coreless linear motor based on additive manufacturing technology, specifically a coreless linear motor winding, which mainly consists of a primary winding 9, a secondary back yoke 10, and a permanent magnet 11. This indicates the pole pitch of a coreless linear motor.

[0049] Example 5:

[0050] A further design feature in this example is that the coil wire routing ensures that the upper and lower ends of the left and right wires form an angle with the effective side. This is to ensure that the ends of the left and right conductors intersect and connect, thus guaranteeing the overall continuity and integrity of the conductor.

[0051] A coreless linear motor using traditional windings has a primary length of p. p is the extreme number. The motor pole pitch is [value], and the motor slot pitch is [value]. The length of one end of the traditional winding is The effective side length of the winding is L.

[0052] This invention relates to a coreless linear motor coil based on additive manufacturing technology, for example, the upper end length is... The length of the lower end is The effective side length of the conductor is L. Clearly, the lengths of the two ends of the coreless linear motor based on additive manufacturing technology are different, and the longer end length is...

[0053] To ensure that the overall volume of the coreless linear motor coil based on additive manufacturing technology is smaller than that of a traditional winding, and to further increase the motor's thrust density, the longer end length of the coreless linear motor coil based on additive manufacturing technology must be shorter than the end length of a traditional winding. The expression is as follows: Right now

[0054] In summary, the included angles between the upper and lower ends and the effective side of this invention must satisfy the following conditions: scope.

[0055] Simulation Example 1

[0056] The following simulation experiments are conducted on three types of motors: a coreless linear motor using conventional windings (referred to as conventional winding CLM), a coreless linear motor using multilayer flat wide conductor windings based on additive manufacturing technology (referred to as AM multilayer flat wide conductor winding CLM, such as...). Figure 9 As shown in Table 1, Table 2, and Table 3, the structure and electromagnetic parameters of each motor are as follows: (Example 4) The coreless linear motor based on additive manufacturing technology using multilayer strip conductor windings (hereinafter referred to as AM multilayer strip conductor winding CLM).

[0057] Table 1 Conventional Winding CLM

[0058] Polar distance 21mm Air gap length 7mm Mechanical air gap length 1mm Axial length 50mm bare wire diameter 0.5mm Number of turns per coil 160 Secondary back yoke thickness 6.5mm Primary length 168mm RMS value of current 5.12A Number of parallel branches 2

[0059] Table 2. CLM based on AM multilayer flat wide conductor winding

[0060] Polar distance 21mm Air gap length 7mm Mechanical air gap length 1.1mm Axial length 50mm wire width 6.94mm conductor thickness 0.77mm Number of coil wires 3 Primary length 168mm Secondary back yoke thickness 6.5mm Number of parallel branches 1 RMS value of current 69.47A Angle between end and effective side 45°

[0061] Table 3. This invention is based on AM multilayer strip conductor winding CLM.

[0062] Polar distance 21mm Air gap length 7mm Mechanical air gap length 1.07mm Axial length 50mm wire width 1.31mm conductor thickness 2.4mm Number of coil wires 5 Primary length 168mm Secondary back yoke thickness 6.5mm Number of parallel branches 1 RMS value of current 40.87A Angle between end and effective side 45°

[0063] The winding conductivity based on AM is 90% IACS. The multilayer flat wide conductor winding coils are stacked, with their effective side length matching the axial length of the permanent magnet. Each slot contains 12 wires. The CLM pole-slot configuration using conventional windings is 8 poles and 6 slots, while the CLM pole-slot configuration using AM multilayer flat wide conductor windings and AM multilayer strip conductor windings is 8 poles and 12 slots. Two-dimensional finite element electromagnetic simulation tests were performed on these three motor structures, applying effective currents of 5.1A, 69.47A, and 40.87A respectively, while maintaining an inductance of 13A / mm² for all three structures. 2 The eddy current loss curve and output thrust curve of the motor under the same load conditions are obtained as follows: Figure 10 (Traditional windings do not consider eddy current losses, so they are not shown in the diagram) and Figure 11 As shown.

[0064] Depend on Figure 10 As can be seen, the eddy current loss of the present invention based on AM multilayer strip conductor winding CLM is reduced by about 190W compared with the existing AM multilayer flat wide conductor winding CLM, and the reverse eddy current braking force of the motor is also greatly reduced. Figure 11 This indicates that the output thrust of the present invention based on AM multilayer strip conductor winding CLM is 93% higher than that of conventional winding CLM, and 66% higher than that of AM multilayer flat wide conductor winding CLM.

[0065] Furthermore, the length of a single end of a conventional winding is 14mm, while the length of a single end of an AM multilayer flat wide conductor winding is approximately 10.5mm. In this invention, the upper end length of the AM multilayer strip conductor winding is approximately 11.2mm, and the lower end length is approximately 9.8mm. The effective side length of all three winding structures is 50mm, and their thrust densities are 1.57 N / cm². 3 2.09 N / cm 3 3.44 N / cm 3 The present invention is based on an AM multilayer strip conductor winding with an overall length comparable to that of an AM multilayer flat wide conductor winding, while reducing the winding length by 25% compared to the traditional winding. At the same time, the thrust density of the motor is greatly improved under the present invention.

Claims

1. A coreless linear motor coil based on additive manufacturing technology, characterized in that, The coil is made of additively manufactured wire, which is composed of several left and right wires connected sequentially. The left and right wires have the same structure, each including an effective side and an end. The end is located on both sides of each effective side and is divided into an upper end and a lower end. Both the effective side and the end are strip-shaped structures, and the upper and lower ends form an angle with the effective side. α The effective sides of the left and right conductors are parallel and of equal length; the total width of all effective sides of the left and right conductors is... / 3, the distance between the two is , The pole pitch of the motor; The wires in the coil are connected by connecting the upper end of the first left wire to the upper end of the first right wire, then connecting the lower end of the first right wire to the lower end of the second left wire, and connecting the upper end of the second left wire to the upper end of the second right wire, and so on, to form a single wire. The distance between each turn of the conductor is 180 electrical degrees, and the coil pitch factor is... k cp =1.

2. The coreless linear motor coil based on additive manufacturing technology according to claim 1, characterized in that, The length of the effective side of the conductor is L Corresponding to the axial length of the motor's permanent magnet; the connected left and right wires are spatially misaligned, with a misalignment distance of [missing information]. C i The distance between adjacent upper and lower ends of the left / right conductor is C es The distance between adjacent valid sides of the left / right traverse is C s ,satisfy The width of the effective side of the left / right conductor is C w Thickness is C t The number of left conductors / right conductors is N ,satisfy The width of the upper and lower ends of the left and right conductors is C we ,satisfy .

3. The coreless linear motor coil based on additive manufacturing technology according to claim 2, characterized in that, The angle between the upper and lower ends and the effective side α satisfy: ,in p The number of poles of the motor. Z This refers to the number of slots in a coreless linear motor with centralized windings.

4. The coreless linear motor coil based on additive manufacturing technology according to claim 3, characterized in that, The distribution factor of the coil is , n This represents the harmonic order.

5. A coreless linear motor winding based on additive manufacturing technology, characterized in that, The windings are distributed structures, and each phase winding includes at least one coreless linear motor coil based on additive manufacturing technology as described in any one of claims 1-4. The coils of each phase winding are arranged horizontally at 60° electrical angle intervals, and the coils are connected in series, in parallel, or in series-parallel according to the winding phase sequence.

6. The coreless linear motor winding based on additive manufacturing technology according to claim 5, characterized in that, The winding phase sequence is arranged according to the AZBXCY array; the number of windings per pole per phase is 1, the winding distribution factor is 1, and the winding factor is [missing value]. ,in, C s This represents the distance between adjacent valid edges of the left / right traverse. C w The width of the effective side of the left / right conductor. The pole pitch of the motor. N The number of left-hand conductors / right-hand conductors. n This represents the harmonic order.

7. A coreless linear motor based on additive manufacturing technology, manufactured using the coreless linear motor winding based on additive manufacturing technology as described in claim 6.

Images