An electromagnetic driving device capable of reducing noise, power consumption and harmonics and a manufacturing method thereof

Abstract

An electromagnetic drive device and a manufacturing method for reducing noise, power consumption and harmonics, comprising a stator and a rotor rotatably connected to the middle of the stator, wherein the stator is provided with a plurality of windings arranged around the circumference of the middle of the stator, and the rotor is provided with a plurality of permanent magnets rotating synchronously with the rotor; the winding is formed by covering a plurality of main enameled wires and a plurality of auxiliary enameled wires, an air gap is formed between adjacent main enameled wires, and the plurality of auxiliary enameled wires are arranged in the air gap of the winding; a plurality of mounting notches for mounting a plurality of permanent magnets are formed on the rotor, and a plurality of through holes are formed on the rotor; compared with the prior art, by filling the auxiliary enameled wires between the air gaps of adjacent main enameled wires, the cross-sectional area of ​​the winding is effectively increased without increasing the area of ​​the stator slot, and the copper loss is reduced, and the main enameled wires are fitted with the auxiliary enameled wires, so as to prevent the generation of harmonics due to the interaction of magnetic fields generated when current is passed due to looseness between the enameled wires.

Description

Technical Field

[0001] The present invention relates to the technical field of permanent magnet synchronous motors, and in particular to an electromagnetic drive device capable of reducing noise, power consumption and harmonics and a manufacturing method thereof. Background Art

[0002] Permanent magnet synchronous motors have the advantages of simple structure, small size, high efficiency and high power factor. Permanent magnet synchronous motors have been used in medium and low voltage motors in the metallurgical industry, ceramic industry, rubber industry, petroleum industry, textile industry and other industries, and have gradually accumulated design and operation experience.

[0003] The air gap magnetic field distortion caused by factors such as the permanent magnet synchronous motor's slot effect, magnetic circuit saturation effect, and winding distribution causes the permanent magnet synchronous motor's back EMF waveform to be distorted and lose its original sinusoidal nature. This distortion will cause the motor's three-phase current to contain a large amount of spatial harmonics.

[0004] At the same time, since there are many current harmonic components in the variable frequency drive system of the permanent magnet synchronous motor, the torque of the motor will pulsate, and the torque pulsation of the motor will also bring vibration and noise. At the same time, the motor core and winding will have additional losses under the action of harmonic current, which will reduce its efficiency and affect the smoothness of the motor operation.

[0005] Due to the effect of harmonics, the power conversion efficiency may be reduced, the motor loss may increase and heat may be generated, and electromagnetic vibration and noise may be generated. The direct consequence is that the motor reliability becomes worse, and the electromagnetic vibration and noise are obvious, which seriously pollutes the operating environment.

[0006] Chinese application number CN202210619988.4 discloses a magnetic field coupling analysis and modulation method of a permanent magnet motor with magnetic field modulation based on a harmonic group. According to the permanent magnet excitation source being an outer surface-mounted permanent magnet and an intermediate permanent magnet, and the armature magnetic source being an outer armature winding, a reference magnetic flux density component of the outer air gap magnetic field of the motor is obtained. According to the permanent magnet excitation source being an inner surface-mounted permanent magnet and an intermediate permanent magnet, and the armature magnetic source being an inner armature winding, a coupling magnetic flux density component of the outer air gap magnetic field is obtained. The coupling effect ratio, harmonic characteristic factor and harmonic coupling efficiency are calculated in turn from the air gap magnetic flux density. Positive and negative coupling harmonics are judged based on the harmonic coupling efficiency. Corresponding positive and negative coupling harmonic groups are established from the positive and negative coupling harmonics, and the positive and negative coupling efficiencies are calculated. Whether the motor magnetic field coupling meets the requirements is analyzed from the positive and negative coupling efficiencies.

[0007] The permanent magnet motor magnetic field disclosed above calculates the positive and negative coupling efficiencies of the harmonic group, analyzes the coupling characteristics of the harmonic group, and modulates the harmonics by adjusting the amplitude and phase of the sinusoidal contour line of the surface-mounted permanent magnet, thereby achieving harmonic adjustment of the motor. This requires calculating and adjusting each permanent magnet motor in turn, which is time-consuming and labor-intensive. Summary of the invention

[0008] The present invention aims to overcome the defects in the prior art and provide an electromagnetic drive device and a manufacturing method thereof which has a stable structure, is safe and reliable, reduces noise and power consumption, and suppresses harmonics.

[0009] In order to achieve the above-mentioned invention object, the present invention adopts the following technical scheme: an electromagnetic drive device with noise reduction, power consumption reduction and harmonic suppression, including a stator and a rotor rotatably connected to the middle part of the stator, the stator is provided with a plurality of windings arranged around the circumference of the middle part of the stator, and the rotor is provided with a plurality of permanent magnets rotating synchronously with the rotor; the winding is formed by covering a plurality of main enameled wires and a plurality of auxiliary enameled wires, an air gap is formed between adjacent main enameled wires, and a plurality of auxiliary enameled wires are arranged in the air gap of the winding; a plurality of installation notches for installing a plurality of permanent magnets are formed on the rotor, and a plurality of through holes are formed on the rotor, and the plurality of through holes and the plurality of installation notches are alternately arranged along the circumferential direction of the middle part of the rotor.

[0010] As a preferred solution of the present invention, a plurality of the main enameled wires are arranged in an array in the winding, and an air gap is formed between four adjacent main enameled wires arranged in the array.

[0011] As a preferred solution of the present invention, an adhesive layer bonded to the main enameled wire is formed on the outer surface of the auxiliary enameled wire, and the auxiliary enameled wire is bonded to four adjacent main enameled wires arranged in an array at the same time.

[0012] As a preferred solution of the present invention, the rotor includes a rotor body and a rotor disk that rotates synchronously with the rotor body, through holes are formed on the rotor body and the rotor disk, and the permanent magnet is installed on the rotor disk.

[0013] As a preferred solution of the present invention, transverse ribs and longitudinal ribs are formed on the rotor body, and transverse clamping grooves clamped with the transverse ribs and longitudinal clamping grooves clamped with the longitudinal ribs are formed on the rotor disk. The transverse ribs and longitudinal ribs are formed at opposite ends of the through hole.

[0014] As a preferred solution of the present invention, a plurality of the through holes are arranged along the axial direction of the rotor disk and the rotor body, and the through holes on the rotor disk and the rotor body are correspondingly connected.

[0015] As a preferred solution of the present invention, the through hole is a waist-shaped hole arranged along the diameter direction of the rotor, and the through hole is formed between adjacent permanent magnets.

[0016] As a preferred solution of the present invention, the plurality of installation notches are through-hole structures formed on the rotor disk, an injection port connected to the installation notches is formed in the middle of the rotor disk, and the outer ring of the rotor disk abuts against the ends of the plurality of permanent magnets to limit the position.

[0017] A method for manufacturing an electromagnetic driving device capable of reducing noise, power consumption and harmonics, comprising the following steps:

[0018] Step A: preparing windings, dividing the main enameled wires into a plurality of columns connected in sequence, each column including a plurality of main enameled wires arranged in a row, and sequentially connecting the plurality of main enameled wires in two adjacent columns through auxiliary enameled wires arranged in a row, and installing the prepared windings in the circumferential direction of the stator;

[0019] Step B: preparing a rotor disk, placing a plurality of permanent magnets on the injection molding plane in advance, ensuring that the bottom surface of the permanent magnets abuts against the injection molding plane, and performing rotor disk injection molding in the middle of the plurality of permanent magnets;

[0020] Step C: preparing a rotor body, preparing the rotor body by injection molding, and reserving and forming through holes, transverse ribs and longitudinal ribs;

[0021] Step D: Assemble the rotor disk and the rotor body to form a rotor, and install the rotor in the middle of the stator.

[0022] As a preferred solution of the present invention, a plurality of the permanent magnets are assembled on the rotor with negative tolerance.

[0023] Compared with the prior art, the invention has the following beneficial effects: by filling the auxiliary enameled wire between the air gaps of adjacent main enameled wires, the cross-sectional area of ​​the winding is effectively increased without increasing the area of ​​the stator slot, and the copper loss is reduced. The main enameled wire and the auxiliary enameled wire are fitted together, so that the magnetic field generated when the current is passed due to the looseness between the enameled wires is prevented from interacting and generating harmonics;

[0024] By setting the rotor disk, each permanent magnet can be clamped under the action of the rotor disk, and the bottom of each permanent magnet is ensured to fit with the rotor body, so as to ensure the consistency of the height difference between the outer circle of the rotor disk and the surface of the permanent magnet, and avoid the magnetic field deviating from the sine wave type due to the inconsistency;

[0025] Through holes are provided on the rotor to suppress eddy current losses caused by harmonics during the rotation of the rotor. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 It is a schematic diagram of the structure of the present invention;

[0027] Figure 2 It is a schematic diagram of the structure of the stator;

[0028] Figure 3 is a schematic diagram of the structure of the rotor disk;

[0029] Figure 4 It is a schematic diagram of the structure of the rotor body;

[0030] Figure 5 is a cross-sectional schematic diagram of the winding;

[0031] Figure numerals: stator 1, winding 11, main enameled wire 12, auxiliary enameled wire 13, bonding layer 14, rotor 2, rotor body 3, transverse rib 31, longitudinal rib 32, rotor disk 4, transverse snap-in groove 41, longitudinal snap-in groove 42, installation notch 43, injection molding port 44, permanent magnet 5, through hole 6. DETAILED DESCRIPTION

[0032] The embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0033] like Figure 1-Figure 5 As shown, an electromagnetic drive device with noise reduction, power consumption reduction and harmonic suppression includes a stator 1 and a rotor 2 rotatably connected to the middle of the stator 1, the stator 1 is provided with a plurality of windings 11 arranged around the circumference of the middle of the stator 1, and the rotor 2 is provided with a plurality of permanent magnets 5 rotating synchronously with the rotor 2; the winding 11 is formed by covering a plurality of main enameled wires 12 and a plurality of auxiliary enameled wires 13, an air gap is formed between adjacent main enameled wires 12, and the plurality of auxiliary enameled wires 13 are arranged in the air gap of the winding 11; a plurality of installation notches 43 for installing a plurality of permanent magnets 5 are formed on the rotor 2, and a plurality of through holes 6 are formed on the rotor 2, and the plurality of through holes 6 and the plurality of installation notches 43 are alternately arranged along the circumferential direction of the middle of the rotor 2.

[0034] The stator 1 is always in a relatively static state, the rotor 2 is rotationally connected to the stator 1, the rotor 2 is rotationally connected to the middle of the stator 1, the permanent magnets 5 rotate synchronously with the rotation of the rotor 2, and the windings 11 are always in a relatively static state.

[0035] The diameter of the main enameled wire 12 is greater than the diameter of the auxiliary enameled wire 13. Several main enameled wires 12 are arranged in an array in the winding 11, and the outer walls of adjacent main enameled wires 12 are abutted against each other. The main enameled wire 12 located in the middle can be abutted against the outer walls of the main enameled wires 12 above, below, left and right at the same time, and an air gap is formed between the four adjacent main enameled wires 12 arranged in the array.

[0036] The size of the auxiliary enameled wire 13 corresponds to the size of the air gap. The auxiliary enameled wire 13 is used to fill the air gap between the four adjacent main enameled wires 12 arranged in an array. At the same time, an adhesive layer 14 that is bonded to the main enameled wire 12 is formed on the outer surface of the auxiliary enameled wire 13. The auxiliary enameled wire 13 is also bonded to the four adjacent main enameled wires 12 arranged in an array.

[0037] The plurality of main enameled wires 12 and the plurality of auxiliary enameled wires 13 are connected under the action of the adhesive layer 14 to ensure the stable arrangement of the overall main enameled wires 12 and the auxiliary enameled wires 13 so as to form the required cross-sectional structure of the winding 11 .

[0038] The auxiliary enameled wires 13 are filled in the air gaps of the main enameled wires 12, so that the cross-sectional area of ​​the winding 11 is effectively increased and the copper loss is reduced without increasing the stator slot area. At the same time, the auxiliary enameled wires 13 are filled between the main enameled wires 12, and the auxiliary enameled wires 13 and the main enameled wires 12 are bonded together by the bonding layer 14, so that the auxiliary enameled wires 13 and the main enameled wires 12 form an integrated structure, thereby preventing the auxiliary enameled wires 13 and the main enameled wires 12 from loosening and generating harmonics due to the interaction of magnetic fields generated when current is passed.

[0039] The rotor 2 includes a rotor body 3 and a rotor disk 4 that rotates synchronously with the rotor body 3 . Through holes 6 are formed on the rotor body 3 and the rotor disk 4 . The permanent magnets 5 are mounted on the rotor disk 4 .

[0040] The rotor disk 4 is located on the surface of the rotor body 3, the bottom of the permanent magnet 5 is in contact with the surface of the rotor body 3, and the permanent magnet 5 is clamped on the rotor disk 4. At the same time, the rotor body 3 synchronously drives the rotor disk 4 and the permanent magnet 5 located on the rotor disk 4 to rotate synchronously during the rotation process.

[0041] The rotor body 3 is formed with transverse ribs 31 and longitudinal ribs 32 , and the rotor disk 4 is formed with transverse snap-in grooves 41 snap-in with the transverse ribs 31 and longitudinal snap-in grooves 42 snap-in with the longitudinal ribs 32 . The transverse ribs 31 and longitudinal ribs 32 are formed at opposite ends of the through hole 6 .

[0042] The transverse rib 31 and the longitudinal rib 32 are protruding structures formed on the rotor body 3. The transverse rib 31 and the longitudinal rib 32 are arranged along the axial direction of the rotor body 3, and under the action of the transverse rib 31 being clamped on the transverse clamping groove 41 and the longitudinal rib 32 being clamped on the longitudinal clamping groove 42, the transverse rib 31 and the longitudinal rib 32 are plugged on the rotor disk 4, thereby synchronously driving the rotor disk 4 to rotate synchronously under the rotation of the rotor body 3.

[0043] A plurality of through holes 6 are arranged along the axial direction of the rotor disk 4 and the rotor body 3. The through holes 6 on the rotor disk 4 and the rotor body 3 are correspondingly connected. The through holes 6 are waist-shaped holes arranged along the diameter direction of the rotor 2. The through holes 6 are formed between adjacent permanent magnets 5. Under the action of the through holes 6, the eddy current loss generated by harmonics in the rotor chip is suppressed.

[0044] The plurality of installation notches 43 are through-hole structures formed on the rotor disk 4 . An injection port 44 communicating with the installation notches 43 is formed in the middle of the rotor disk 4 . The outer ring of the rotor disk 4 abuts against the ends of the plurality of permanent magnets 5 to limit the position.

[0045] A method for manufacturing an electromagnetic driving device capable of reducing noise, power consumption and harmonics, comprising the following steps:

[0046] Step A: Prepare the winding 11, divide the main enameled wire 12 into several columns connected in sequence, each column includes several main enameled wires 12 arranged in a row, and connect the several main enameled wires 12 of two adjacent columns in sequence through the auxiliary enameled wires 13 arranged in a row, and install the prepared winding 11 in the circumferential direction of the stator 1.

[0047] The number of columns of the main enameled wires 12 and the number of main enameled wires 12 in each row are set according to actual needs, and the number of main enameled wires 12 in each column is consistent. The overall winding 11 forms a rectangular cross-sectional structure, and the cross-sectional size of the winding 11 is increased as much as possible, thereby increasing the magnetic field strength generated by the winding 11 as much as possible.

[0048] During the assembly process of the main enameled wire 12 and the auxiliary enameled wire 13, the main enameled wire 12 and the auxiliary enameled wire 13 are assembled in sequence to form a plurality of main enameled wires 12 and a plurality of auxiliary enameled wires 13 arranged in rows, and at this time, the plurality of main enameled wires 12 and a plurality of auxiliary enameled wires 13 arranged in rows are alternately bonded in sequence through the bonding layer 14, and the main enameled wires 12 of the next column are bonded between adjacent auxiliary enameled wires 13 to form the installation of the plurality of main enameled wires 12 arranged in rows in the next column, and the auxiliary enameled wires 13 of the next column are bonded between adjacent auxiliary enameled wires 13 to form the installation of the plurality of auxiliary enameled wires 13 arranged in rows in the next column, and the above-mentioned installation method is repeated to realize the combined connection of the array-type main enameled wires 12 and auxiliary enameled wires 13.

[0049] Step B: Prepare the rotor disk 4, place several permanent magnets 5 on the injection molding plane in advance, ensure that the bottom surface of the permanent magnet 5 is in contact with the injection molding plane, and perform rotor disk 4 injection molding in the middle of several permanent magnets 5 to ensure the flatness of the bottom of the permanent magnet 5, thereby ensuring that the height difference between the surfaces of each permanent magnet 5 is consistent, reducing the deviation of the magnetic field from the sinusoidal waveform.

[0050] By performing the rotor disk 4 injection molding in the middle of a plurality of permanent magnets 5, the liquid plastic material flows from the inside to the outside, pushing the permanent magnets to move from the inside to the outside, and the outward movement position of the permanent magnets 5 is limited under the action of the injection mold, ensuring that all permanent magnets are against the inner wall of the injection mold, avoiding the inconsistent height difference between the outer circle of the rotor disk 4 and the surface of the permanent magnet, so that the rotor forms a more ideal sine wave.

[0051] Step C: Prepare the rotor body 3. The rotor body 3 is prepared by injection molding, and a through hole 6, a transverse rib 31 and a longitudinal rib 32 are reserved. The rotor body 3 is independently manufactured, and there is no need to consider the installation method of the permanent magnet 5. Therefore, a higher precision rotor body 3 can be obtained, and the smooth surface of the rotor body 3 can effectively reduce the noise and vibration of the rotor during rotation.

[0052] Step D: Assemble the rotor disk 4 and the rotor body 3 to form the rotor 2 , and install the rotor 2 in the middle of the stator 1 .

[0053] A plurality of permanent magnets 5 are assembled on the rotor disk 4 with a negative tolerance, which is generally -0.1 to -0.4, to ensure stable installation of the permanent magnets 5 on the rotor disk 4.

[0054] The above description of the disclosed embodiments enables one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention; therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

[0055] Although the present invention uses more reference numerals in the figures: stator 1, winding 11, main enameled wire 12, auxiliary enameled wire 13, bonding layer 14, rotor 2, rotor body 3, transverse rib 31, longitudinal rib 32, rotor disk 4, transverse snap-fit ​​groove 41, longitudinal snap-fit ​​groove 42, installation notch 43, injection port 44, permanent magnet 5, through hole 6, etc., the possibility of using other terms is not excluded. These terms are used only to more conveniently describe and explain the essence of the present invention; interpreting them as any additional limitation is contrary to the spirit of the present invention.

Claims

1. An electromagnetic drive device capable of reducing noise, power consumption and harmonics, comprising a stator (1) and a rotor (2) rotatably connected to the middle of the stator (1), the stator (1) being provided with a plurality of windings (11) arranged around the circumference of the middle of the stator (1), and the rotor (2) being provided with a plurality of permanent magnets (5) rotating synchronously with the rotor (2); characterized in that: The winding (11) is formed by coating a plurality of main enameled wires (12) and a plurality of auxiliary enameled wires (13), an air gap is formed between adjacent main enameled wires (12), and the plurality of auxiliary enameled wires (13) are arranged in the air gap of the winding (11); a plurality of mounting notches (43) for mounting a plurality of permanent magnets (5) are formed on the rotor (2), and a plurality of through holes (6) are formed on the rotor (2), and the plurality of through holes (6) and the plurality of mounting notches (43) are alternately arranged along the circumferential direction of the middle part of the rotor (2); the rotor (2) comprises a rotor body (3) and a rotor disk (4) that rotates synchronously with the rotor body (3), the through holes (6) are formed on the rotor body (3) and the rotor disk (4), and the permanent magnets (5) are mounted on the rotor disk (4); the rotor disk (4) is located on the surface of the rotor body (3), and the bottom of the permanent magnets (5) is aligned with the surface of the rotor body (3). The rotor disc (4) is abutted against the permanent magnet (5), and the permanent magnet (5) is arranged on the rotor disc (4) in a snap-fit ​​manner. At the same time, the rotor body (3) synchronously drives the rotor disc (4) and the permanent magnet (5) located on the rotor disc (4) to rotate synchronously during the rotation process; the plurality of installation notches (43) are through-hole structures formed on the rotor disc (4), and an injection molding port (44) connected to the installation notch (43) is formed in the middle of the rotor disc (4). The outer ring of the rotor disc (4) abuts against the ends of the plurality of permanent magnets (5) to limit the position; the plurality of permanent magnets (5) are pre-placed on the injection molding plane to ensure that the bottom surface of the permanent magnet (5) abuts against the injection molding plane, and the rotor disc (4) is injection molded in the middle of the plurality of permanent magnets (5) to form the rotor disc (4); the plurality of through holes (6) are arranged along the axial direction of the rotor disc (4) and the rotor body (3), and the through holes (6) on the rotor disc (4) and the rotor body (3) are correspondingly connected.

2. The electromagnetic driving device with noise reduction, power consumption reduction and harmonic suppression according to claim 1, characterized in that: A plurality of the main enameled wires (12) are arranged in an array within the winding (11), and an air gap is formed between four adjacent main enameled wires (12) arranged in the array.

3. The electromagnetic driving device with noise reduction, power consumption reduction and harmonic suppression according to claim 2, characterized in that: An adhesive layer (14) that is bonded to the main enameled wire (12) is formed on the outer surface of the auxiliary enameled wire (13), and the auxiliary enameled wire (13) is bonded to four adjacent main enameled wires (12) arranged in an array at the same time.

4. The electromagnetic driving device with noise reduction, power consumption reduction and harmonic suppression according to claim 3, characterized in that: The rotor body (3) is formed with a transverse convex rib (31) and a longitudinal convex rib (32); the rotor disk (4) is formed with a transverse clamping groove (41) clamped with the transverse convex rib (31) and a longitudinal clamping groove (42) clamped with the longitudinal convex rib (32); the transverse convex rib (31) and the longitudinal convex rib (32) are formed at opposite ends of the through hole (6).

5. The electromagnetic driving device with noise reduction, power consumption reduction and harmonic suppression according to claim 1, characterized in that: The through hole (6) is a waist-shaped hole arranged along the diameter direction of the rotor (2), and the through hole (6) is formed between adjacent permanent magnets (5).

6. A method for manufacturing an electromagnetic drive device with noise reduction, power consumption reduction and harmonic suppression, characterized in that: The electromagnetic driving device for reducing noise, power consumption and harmonics as claimed in any one of claims 1 to 5 comprises the following steps: Step A: preparing a winding (11), dividing the main enameled wires (12) into a plurality of columns connected in sequence, each column comprising a plurality of main enameled wires (12) arranged in a row, and sequentially connecting the plurality of main enameled wires (12) in two adjacent columns via auxiliary enameled wires (13) arranged in a row, and installing the prepared winding (11) in the circumferential direction of the stator (1); Step B: preparing a rotor disk (4), placing a plurality of permanent magnets (5) on an injection molding plane in advance, ensuring that the bottom surface of the permanent magnets (5) abuts against the injection molding plane, and performing injection molding of the rotor disk (4) in the middle of the plurality of permanent magnets (5); Step C: preparing a rotor body (3), preparing the rotor body (3) by injection molding, and pre-forming a through hole (6), a transverse convex rib (31), and a longitudinal convex rib (32); Step D: Assemble the rotor disk (4) and the rotor body (3) to form a rotor (2), and install the rotor (2) in the middle of the stator (1).

7. The method for manufacturing an electromagnetic drive device capable of reducing noise, power consumption and harmonics according to claim 6, characterized in that: The plurality of permanent magnets (5) are assembled on the rotor disk (4) with negative tolerance.

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