Assembly method of low voltage and high power unequal turns coil

Abstract

The present invention relates to an assembly method of a low-voltage, high-power, unequal-turn coil, and belongs to the technical field of motor manufacturing. The present invention uses a winding mold to continuously wind the unequal-turn coil. During winding, the coil under each pole and each phase is regarded as a connected coil, and the number of turns in each slot on the winding mold is unequal; after winding, the wire is laid in the core slot, and epoxy glass cloth tubes are inserted into the slots with low slot fill rate to reduce the gap in the slot, so that the heat dissipation effect of the motor is improved. The present invention can solve the problem of setting the number of turns of the stator coil of a low-voltage, high-power motor.

Description

Technical Field

[0001] The invention relates to the technical field of motor manufacturing, in particular to an assembly method of a low-voltage and high-power unequal-turn coil. Background Art

[0002] For low-voltage, high-power motors, a common problem is that the number of coil turns is small. Under the existing technology, equal-turn coils are often used, and the number of turns of each coil is the same. However, in actual applications, due to different motor operating conditions and performance requirements, the number of coil turns needs to be adjusted to achieve optimal performance. However, in the design of equal-turn coils, adjusting the number of turns often faces many difficulties, such as increased design complexity, increased manufacturing costs, and performance loss.

[0003] To solve this problem, the current solution is to adjust the number of coil turns by adjusting the length of the core. Although this method can achieve the change of the number of turns to a certain extent, it also brings new problems: adjusting the length of the core requires increasing or decreasing the core material, resulting in material waste and increasing production costs.

[0004] Therefore, it is extremely urgent to develop an assembly method for low-voltage, high-power unequal-turn coils. Summary of the invention

[0005] In view of the shortcomings of the above-mentioned existing production technology, the applicant provides a method for assembling a low-voltage, high-power, unequal-turn coil, thereby solving the problem of setting the number of turns of the stator coil of a low-voltage, high-power motor.

[0006] The technical solution adopted by the present invention is as follows: a method for assembling a low-voltage, high-power, unequal-turn coil, comprising the following steps:

[0007] Step 1: Multiple enameled wires are assembled into a bundle and wound continuously from left to right on the winding mold. When winding, the coils under each pole and each phase are regarded as a connected coil, and the number of turns in each slot on the winding mold is not equal;

[0008] Step 2: Remove the coil from the winding mold, mark the number of turns of the coil, and the production of a coil is completed;

[0009] Step 3: Place the slot bottom insulation in the core slot, with both ends of the slot bottom insulation extending out of the core;

[0010] Step 4: Place the lower edges of the coils of a coil chain into the deepest part of the slots one by one until all the lower edges of the slots in the lower layer are placed;

[0011] Step 5: The number of turns of the coil in the slot is 2N or 2N+1. When the number of turns of the coil in the slot is 2N, an epoxy glass cloth tube is placed in the slot;

[0012] Step 6: Lay interlayer insulation in the middle of the core slot, and the interlayer insulation completely covers the lower layer in the slot;

[0013] Step 7: Place the upper edge of the coil of the next coil in the upper layer of the slot in the core slot;

[0014] Step 8: After the line is lowered, slot wedges are driven into the slots of the core slots, and finally the bridge wires are straightened out and tied and pressed.

[0015] As a further improvement of the above technical solution:

[0016] Preferably, the structure of the winding mold in step one is: comprising a plurality of assembly plates arranged vertically, the plurality of assembly plates being connected by assembly bolts; and a winding groove is formed between every two assembly plates.

[0017] Preferably, the assembly plate is a hexagonal structure, including two opposite oblique sides forming an upper end, two opposite oblique sides forming a lower end, and two sides formed by straight line portions.

[0018] Preferably, the structure of the coil produced in step 2 includes a lower edge of the coil, an upper edge of the coil and a coil lead, and a turn number mark is set on the coil.

[0019] Preferably, the lower side of the coil and the upper side of the coil are both straight lines.

[0020] Preferably, in step three, the length of both ends of the slot bottom insulation extending out of the iron core is 2-5 cm.

[0021] Preferably, N in step five is the number of turns of each coil, and N is an integer.

[0022] Preferably, the slot wedge in step eight is a magnetic slot wedge.

[0023] Preferably, after the winding is completed in step eight, the number of turns of the upper and lower layers of coils in the core slot fluctuates by less than or equal to one turn.

[0024] The beneficial effects of the present invention are as follows:

[0025] The present invention has a compact structure and is easy to assemble and operate. The number of coil turns in each pole phase group of the present invention is arranged differently to achieve a maximum slot occupancy rate. At the same time, the magnetomotive force of each phase winding under each pair of poles is distributed sinusoidally along the circumference of the stator slot, which effectively weakens the stator magnetomotive force harmonics and improves the efficiency of the motor.

[0026] The present invention also has the following advantages:

[0027] In view of the situation that the gaps in some slots are relatively large, the present invention adds epoxy glass cloth tubes for interlayer filling, reduces the gaps in the slots, and improves the heat dissipation effect of the motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a schematic diagram of the stator body after binding and pressing of the present invention.

[0029] Figure 2 It is a schematic diagram of the core slot arrangement of the present invention.

[0030] Figure 3 It is a schematic diagram of the structure of a coil of the present invention.

[0031] Figure 4 It is a schematic diagram of the winding mold structure of the present invention.

[0032] Figure 5 Schematic diagram of the winding magnetomotive force generated in an embodiment of the present invention.

[0033] Figure 6 Schematic diagram of harmonic distribution in an embodiment of the present invention.

[0034] Among them: 1. stator body; 2. core slot; 3. interlayer insulation; 4. lower layer in slot; 5. upper layer in slot; 6. epoxy glass cloth tube; 7. single coil; 8. winding mold;

[0035] 21. Slot bottom insulation; 22. Slot wedge;

[0036] 71. Coil lower edge; 72. Coil upper edge; 73. Turns mark; 74. Coil lead wire;

[0037] 81. Assembly plate; 82. Assembly bolts; 83. Winding groove. DETAILED DESCRIPTION

[0038] The specific implementation of the present invention will be described below in conjunction with the accompanying drawings.

[0039] like Figure 1 to Figure 6 As shown, the assembly method of the low-voltage high-power unequal-turn coil of this embodiment includes the following steps:

[0040] Step 1: Multiple enameled wires are assembled into a wire bundle and are continuously wound from left to right on a winding mold 8. During winding, the coils under each pole and each phase are regarded as a connected coil 7, and the number of turns in each slot on the winding mold 8 is not equal;

[0041] Step 2: Remove the coil from the winding mold 8, mark the number of turns of the coil, and the production of a single-link coil 7 is completed;

[0042] Step 3: Place the slot bottom insulation 21 in the core slot 2, with both ends of the slot bottom insulation 21 extending out of the core, and the length of both ends of the slot bottom insulation 21 extending out of the core is 2-5 cm;

[0043] Step 4: Place the lower edge 71 of the coil 7 in a row into the deepest part of the slot one by one, until the lower edges of all the slots in the lower layer 4 of the slot are placed;

[0044] Step 5: The number of turns of the coil in the slot is divided into 2N or 2N+1. When the number of turns of the coil in the slot is 2N, an epoxy glass cloth tube 6 is padded in the slot, where N is the number of turns of each coil and N is an integer; the epoxy glass cloth tube 6 can fill the gap and improve the heat dissipation effect of the motor;

[0045] Step 6: Lay interlayer insulation 3 in the middle of the core slot 2, and the interlayer insulation 3 completely covers the lower layer 4 in the slot;

[0046] Step 7: Place the upper edge 72 of the coil 7 under the upper layer 5 in the core slot 2;

[0047] Step 8: After the line is lowered, a slot wedge 22 is driven into the slot of the core slot 2, and finally the bridge wire is straightened and tied and pressed. The slot wedge 22 is a magnetic slot wedge.

[0048] In this embodiment, the structure of the winding mold 8 in step one is: it includes a plurality of assembly plates 81 arranged vertically, and the plurality of assembly plates 81 are connected by assembly bolts 82; a winding groove 83 is formed between every two assembly plates 81; the assembly plate 81 is a hexagonal structure, including two opposite oblique sides forming an upper end, two opposite oblique sides forming a lower end, and two sides formed by straight line parts.

[0049] In this embodiment, the structure of the coil 7 produced in step 2 is: including the lower edge 71 of the coil, the upper edge 72 of the coil and the coil lead 74, and a turn number mark 73 is also set on the coil; the lower edge 71 of the coil and the upper edge 72 of the coil are both straight lines.

[0050] In this embodiment, after the winding is completed in step eight, the number of turns of the upper and lower layers of coils in the core slot 2 fluctuates to be less than or equal to one turn.

[0051] In this embodiment, specifically, a stator body 1 is included, the stator body includes 6 phase belts, each phase belt has Q stator slots, each stator slot is wound with a coil, and the number of coil turns wound in the Q stator slots in one phase belt is not equal, such as Figure 3-4 As shown, when winding, the coils under each pole and each phase are regarded as a group, and each group of coils is wound continuously.

[0052] In this embodiment, specifically, in order to control the slot fill rate, the difference in the number of turns in each coil in each coil connection is less than or equal to one turn. After the offline is completed, the number of turns of the upper and lower layers of coils in the core slot 2 fluctuates by less than or equal to one turn, and the number of turns of the coil in the slot exists in two states: 2N and 2N+1.

[0053] The number of coils per connection is equal to the number of slots per phase belt, which is Q, and the value range of Q is 3 to 8; the number of turns of each coil is N (N is an integer); when the coil is wound, the relationship between Q and N corresponds to the rules in Table 1:

[0054] Table 1:

[0055]

[0056] According to the content of Table 1, taking a squirrel cage three-phase AC motor with 24 slots, 2 poles and short span of 11 slots as an example, the number of slots per pole per phase is Q=4, the number of turns per pole per phase is 17=4N+1, N=4, and Q=4 is substituted into the table, and the arrangement of the number of coil turns is 4, 4, 4, 5; in this example, there are only 8 turns and 9 turns in the upper and lower layers of the coil in the slot, and there will be no waste of slot space caused by 10 turns; Figure 5 The winding magnetomotive force generated in this example is shown in Figure 1. Figure 6 Shown is the harmonic distribution diagram for this example.

[0057] Combining the above specific examples and Figure 5 and Figure 6 It can be seen from the contents that the present invention can make the magnetomotive force of each phase winding under each pair of poles present a sinusoidal distribution along the circumference of the stator slot, effectively weakening the stator magnetomotive force harmonics.

[0058] The above description is an explanation of the present invention, not a limitation of the present invention. The scope of the present invention is defined in the claims. Any form of modification may be made within the scope of protection of the present invention.

Claims

1. A method for assembling a low-voltage, high-power, unequal-turn coil, characterized in that: The following steps are involved: Step 1: assemble a plurality of enameled wires into a wire bundle and continuously wind them from left to right on a winding mold (8), wherein the coils under each pole and each phase are regarded as a connected coil (7), and the number of turns in each slot on the winding mold (8) is not equal; Step 2: Remove the coil from the winding mold (8), mark the number of turns of the coil, and the production of a coil (7) is completed; Step 3: placing a slot bottom insulator (21) in the core slot (2), with both ends of the slot bottom insulator (21) extending out of the core; Step 4: Place the lower edges (71) of the coils (7) of a group of coils into the deepest part of the slots one by one, until the lower edges of all the slots in the lower layer (4) of the slots are placed; Step 5: The number of turns of the coil in the slot is divided into 2N or 2N+1. When the number of turns of the coil in the slot is 2N, an epoxy glass cloth tube (6) is inserted into the slot; Step 6: Lay interlayer insulation (3) in the middle of the core slot (2), and the interlayer insulation (3) completely covers the lower layer (4) in the slot; Step 7: placing the upper edge (72) of the coil of the next coil (7) in the upper layer (5) of the slot in the core slot (2); Step 8: After the wire is lowered, a slot wedge (22) is driven into the notch of the core slot (2), and finally the bridge wire is straightened and tied and pressed.

2. The method for assembling a low-voltage, high-power, unequal-turn coil according to claim 1, characterized in that: The structure of the winding mold (8) in step 1 is: comprising a plurality of assembly plates (81) arranged vertically, and the plurality of assembly plates (81) are connected by assembly bolts (82); A winding groove (83) is formed between every two assembly plates (81).

3. The method for assembling a low-voltage, high-power, unequal-turn coil according to claim 2, characterized in that: The assembly plate (81) is a hexagonal structure, including two opposite oblique sides forming an upper end, two opposite oblique sides forming a lower end, and two sides formed by straight line parts forming side parts.

4. The method for assembling a low-voltage, high-power, unequal-turn coil according to claim 1, characterized in that: The structure of the coil (7) manufactured in step 2 includes a coil lower edge (71), a coil upper edge (72) and a coil lead (74), and a turn number mark (73) is also set on the coil.

5. The method for assembling a low-voltage, high-power, unequal-turn coil according to claim 4, characterized in that: The coil lower layer side (71) and the coil upper layer side (72) are both straight lines.

6. The method for assembling a low-voltage, high-power, unequal-turn coil according to claim 1, characterized in that: In the step 3, the length of the two ends of the slot bottom insulation (21) extending out of the iron core is 2-5 cm.

7. The method for assembling a low-voltage, high-power, unequal-turn coil according to claim 1, characterized in that: In step 5, N is the number of turns of each coil, and N is an integer.

8. The method for assembling a low-voltage, high-power, unequal-turn coil according to claim 1, characterized in that: The slot wedge (22) in step eight is a magnetic slot wedge.

9. The method for assembling a low-voltage, high-power, unequal-turn coil according to claim 1, characterized in that: After the winding is completed in step eight, the number of turns of the upper and lower layers of coils in the core slot (2) fluctuates to be less than or equal to one turn.

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