Slotless magnetic element manufacturing method and slotless magnetic element

Abstract

The invention relates to the technical field of slotless electromagnetic elements, in particular to a slotless magnetic element manufacturing method and a slotless magnetic element, and aims to solve the problems that when an existing coreless magnetic element is manufactured, a large number of molds need to be used, and the strength is low. The manufacturing method provided by the invention comprises the following steps: winding a matrix strip on the surface of a cylindrical mold to form a ring shape and reach a first set thickness, then placing a prefabricated winding on the surface of the matrix strip, and finally continuously winding the matrix strip to reach a second set thickness so as to fix the prefabricated winding. The prefabricated winding is fixed by adopting a prefabricated winding process, so that the magnetic element is better fused with the motor structure to realize integration, the structural strength of the magnetic element is improved, the safety, applicability and durability of the motor are improved, the process is simplified, the axial and circumferential mechanical strength is improved, and the service life of equipment is prolonged. And meanwhile, only one cylindrical mold is needed, so that the number of molds is greatly reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of slotless electromagnetic components, and in particular to a slotless magnetic component manufacturing method and the slotless magnetic component. Background Art

[0002] Electromagnetic components refer to electromagnetic induction components that contain winding structures, such as motor armatures, excitation rotors, transformers, and inductors. Electromagnetic components can be one magnetic component or two or more magnetic components. They are essential components for energy storage, conversion, and isolation, and are often used as transformers or inductors. When used as a transformer, electromagnetic components can play the following roles: electrical isolation; voltage conversion to achieve the purpose of voltage rise and fall; realize secondary phase shift of high-power transformers, which is conducive to reducing ripple factors; transmit energy through magnetic coupling; and facilitate the measurement of voltage and current. When used as an inductor, electromagnetic components can play the following roles: energy storage, smoothing, filtering; suppressing peak voltage or current, protecting electronic components that are easily damaged by voltage and current; resonating with capacitors to generate voltage or current with alternating directions.

[0003] Magnetic components are essential components in switching converters, but it is not easy to thoroughly understand their working conditions. Their working conditions include the nonlinearity of magnetic material characteristics, the dependence of characteristics on temperature, frequency, and air gap, and the difficulty of measurement. When selecting, there are no ready-made products to choose from like electronic components. There are many parameters for transformer and inductor design, such as voltage, current, frequency, temperature, energy, inductance, ratio, leakage inductance, magnetic material parameters, copper loss, iron loss, volume, etc., so most magnetic components must be designed by themselves, which is a more complicated link in the power supply design process.

[0004] The motor is mainly composed of a stator, a rotor, a bearing, and a brush slip ring. The stator is mainly composed of a base, an armature enclosure, and an armature. The armature is a typical magnetic component, and the rotor is mainly composed of a shaft, an excitation structure, etc. The magnetic component is an indispensable structural component for realizing the function of the motor. The magnetic component is exposed to the magnetic field. When discharging, the torque of the motor is mainly borne by the magnetic component and transmitted to the base through the armature magnetic component enclosure. Therefore, the stability of the magnetic component structure is very important.

[0005] There are two types of magnetic components: coreless and cored. In practical applications, coreless magnetic components are generally molded by injection molding, which requires a large number of molds and has low strength. Summary of the invention

[0006] The object of the present invention is to provide a method for manufacturing a slotless magnetic component and a slotless magnetic component, so as to solve the problem that a large number of molds are needed and the strength is low when manufacturing the existing coreless magnetic component.

[0007] In order to solve the above technical problems, the technical solution provided by the present invention is:

[0008] A method for manufacturing a slotless magnetic element comprises the following steps:

[0009] The base strip is wound into a ring shape on the surface of a cylindrical mold to a first set thickness, and then the prefabricated winding is placed on the surface of the base strip. Finally, the base strip is continued to be wound to a second set thickness to fix the prefabricated winding.

[0010] Furthermore, the material of the base strip is one or more of a composite material, an insulating material or a metal material, and the material of the base strip in contact with the prefabricated winding is an insulating material.

[0011] Furthermore, the composite material is carbon fiber T300, the insulating material is insulating mica, and the metal material is silicon steel.

[0012] Optionally, when making a slotless magnetic element of a wave winding, the base strip is wound on the surface of a cylindrical mold to a first set thickness, and then the prefabricated winding is placed on the surface of the base strip. The base strip is then inserted into the annular hole along the length direction of the prefabricated winding and wound, and finally the base strip is continued to be wound to a second set thickness to fix the prefabricated winding.

[0013] Optionally, when making a slotless magnetic component with a stacked winding, the base strip is wound on the surface of a cylindrical mold to a first set thickness, then the prefabricated winding is placed on the surface of the base strip and wound around the axis of the cylindrical mold, and finally the base strip is wound to a second set thickness to fix the prefabricated winding.

[0014] Optionally, when manufacturing a slotless magnetic element of a concentric winding, the prefabricated winding is set as a continuous S-shaped belt-type prefabricated flexible winding;

[0015] The base strip is wound on the surface of the cylindrical mold into a ring shape to a first set thickness, and then the prefabricated flexible winding is placed on the surface of the wound base strip, the length direction of the prefabricated flexible winding is not perpendicular to the axis direction of the cylindrical mold, and this section of the prefabricated flexible winding is the first section of the winding;

[0016] Continue to wind the base strip to a second set thickness to fix the first winding section, then fold the prefabricated flexible winding to form a ring coil with the first winding section, and take the winding section that forms the ring coil with the first winding section after folding as the second winding section, and then continue to wind the base strip to a second set thickness to fix the second winding section;

[0017] The first winding section and the second winding section are connected end to end to form an S-shaped structure.

[0018] Further, the prefabricated flexible winding is repeatedly folded and the base strip is wound to form a plurality of coaxial annular coils arranged radially along the cylindrical mold.

[0019] Furthermore, a plurality of annular coils distributed radially along the cylindrical mold are formed by continuously folding a strip-shaped prefabricated flexible winding.

[0020] Furthermore, a plurality of coaxial annular coils arranged radially along the cylindrical mold are grouped as one group, and the plurality of groups of annular coils are evenly distributed around the axis of the cylindrical mold.

[0021] Another aspect of the present invention provides a slotless magnetic component manufactured by the above-mentioned slotless magnetic component manufacturing method, comprising a base structure and a winding; the base structure is formed by winding a base strip, and the winding is wrapped and fixed inside during the winding process.

[0022] Based on the above technical solutions, the technical effects that can be achieved by the present invention are:

[0023] The method for manufacturing a slotless magnetic element provided by the present invention comprises the following steps: winding a base strip into a ring shape on a cylindrical mold surface to a first set thickness, then placing a prefabricated winding on the surface of the base strip, and finally continuing to wind the base strip to a second set thickness to fix the prefabricated winding.

[0024] The slotless magnetic component manufacturing method provided by the present invention adopts a prefabricated winding process to fix the prefabricated winding, so that the magnetic component can be better integrated with the motor structure to achieve integration, improve the structural strength of the magnetic component, increase the safety, applicability and durability of the motor, simplify the process, improve the axial and circumferential mechanical strength, and increase the service life of the equipment. At the same time, only one cylindrical mold is required, which greatly reduces the number of molds. Similarly, magnetic components with iron cores can also be improved by the above method.

[0025] This method is applicable to both stators and rotors. The magnetic element and the motor structure are formed into one piece through winding, thus avoiding the problems of complicated procedures, high equipment costs, incomplete insulation coating, etc. in the prior art, reducing production costs and improving the reliability of motor applicability. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In order to more clearly illustrate the specific implementation methods of the present invention or the technical solutions in the prior art, the drawings required for use in the specific implementation methods or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some implementation methods of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0027] Figure 1 A schematic diagram of a method for manufacturing a slotless magnetic element provided by an embodiment of the present invention;

[0028] Figure 2 It is the overall structural diagram of the motor;

[0029] Figure 3 A schematic diagram of a strip-type prefabricated winding structure for making a concentric winding;

[0030] Figure 4 A schematic diagram of a strip-type prefabricated winding structure for making a stacked winding;

[0031] Figure 5 A schematic diagram of a strip-type prefabricated winding structure for making a wave winding;

[0032] Figure 6 It is a schematic diagram of the structure of a magnetic element with a tile-like stacked structure;

[0033] Figure 7 It is a schematic diagram of the structure of a spirally wound laminated structure magnetic element;

[0034] Figure 8 It is a schematic diagram of the structure of a radially stacked magnetic element;

[0035] Fig. 9 It is a schematic diagram of the concentric coil winding process;

[0036] Fig.10 It is a schematic diagram of forming a concentric coil arranged along the circumferential direction;

[0037] Fig.11 It is a schematic diagram of the structure of the concentric coils arranged along the circumferential direction;

[0038] Fig.12 This is a schematic diagram of the forming of a single complete concentric coil;

[0039] Fig.13 It is a schematic diagram of the folding and winding of the concentric coil;

[0040] Fig.14 Schematic diagram of the forming process of the wound wave winding flexible magnetic element.

[0041] Icons: 110, machine base; 120, armature housing; 130, armature winding; 140, field winding. DETAILED DESCRIPTION

[0042] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings here can be arranged and designed in various different configurations.

[0043] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention claimed for protection, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0044] Some embodiments of the present invention are described in detail below in conjunction with the accompanying drawings. In the absence of conflict, the following embodiments and features in the embodiments can be combined with each other.

[0045] The existing coreless magnetic components require a large number of molds to be manufactured and have low strength.

[0046] In view of this, the present invention provides a method for manufacturing a slotless magnetic component, comprising the following steps: winding a base strip into a ring shape on a cylindrical mold surface to a first set thickness, then placing a prefabricated winding on the surface of the base strip, and finally continuing to wind the base strip to a second set thickness to fix the prefabricated winding.

[0047] The slotless magnetic component manufacturing method provided by the present invention adopts a prefabricated winding process to fix the prefabricated winding, so that the magnetic component can be better integrated with the motor structure to achieve integration, improve the structural strength of the magnetic component, increase the safety, applicability and durability of the motor, simplify the process, improve the axial and circumferential mechanical strength, and increase the service life of the equipment. At the same time, only one cylindrical mold is required, which greatly reduces the number of molds. Similarly, magnetic components with iron cores can also be improved by the above method.

[0048] This method is applicable to both stators and rotors. The magnetic element and the motor structure are formed into one piece through winding, thus avoiding the problems of complicated procedures, high equipment costs, incomplete insulation coating, etc. in the prior art, reducing production costs and improving the reliability of motor applicability.

[0049] The following combination Figure 1-Figure 14 The method for manufacturing the slotless magnetic element provided in this embodiment is described in detail:

[0050] The motor as a whole comprises a base 110, an armature housing 120, an armature winding 130 and an excitation winding 140. Figure 2 shown.

[0051] In this embodiment, the material of the base strip is one or more of a composite material, an insulating material or a metal material, and the material of the base strip in contact with the prefabricated winding is an insulating material. Specifically, the composite material is carbon fiber T300, the insulating material is insulating mica, and the metal material is silicon steel.

[0052] The magnetic element in this embodiment adopts a stacked structure, such as Figure 6 , Figure 7 , Figure 8 As shown, the conductive layer is composed of prefabricated windings, which can be manufactured into complete winding structures such as concentric windings, lap windings or wave windings, such as Figure 3 , Figure 4 , Figure 5 As shown. The prefabricated windings are all thin-strip prefabricated flexible windings, such as Figure 3 , Figure 4 , Figure 5 As shown, it can reduce the eddy current loss on the conductor, enhance the insulation between the wires, increase the starting voltage of the local discharge between the turns, and has the function of anti-corona; at the same time, the thin-strip prefabricated flexible winding has good mechanical properties, has stronger impact resistance than ordinary wires, and the insulation between turns is not easily damaged.

[0053] In this embodiment, the base strip material is wrapped between the layers of the thin strip type prefabricated flexible winding by using a layer-by-layer winding process, so that the magnetic element forms a whole.

[0054] Embodiment 1

[0055] When manufacturing the slotless magnetic element of the wave winding, the base strip is wound on the surface of the cylindrical mold to a first set thickness, and then the prefabricated winding is placed on the surface of the base strip. Subsequently, the base strip is inserted into the annular hole of the prefabricated winding along the length direction and wound, so that the prefabricated winding is wound on the cylindrical mold, and finally the base strip is continued to be wound to a second set thickness to fix the prefabricated winding, so as to obtain a radially laminated structure magnetic element, such as Fig.14 shown.

[0056] Embodiment 2

[0057] When manufacturing a slotless magnetic component with stacked windings, the base strip is wound on the surface of a cylindrical mold to a first set thickness, and then the prefabricated winding is placed on the surface of the base strip and wound around the axis of the cylindrical mold, and finally the base strip is wound to a second set thickness to fix the prefabricated winding, so as to obtain a spirally wound laminated structure magnetic component, such as Figure 7 It should be noted that a base tape of insulating material is wound between each layer of the stacked winding to prevent interlayer conduction. When winding the prefabricated winding, the prefabricated winding and the base tape can be combined into a double-layer tape for easy winding.

[0058] Embodiment 3

[0059] When manufacturing a slotless magnetic component with concentric winding, the prefabricated winding is set as a continuous S-shaped belt-type prefabricated flexible winding, such as Figure 3 The base strip is wound on the surface of the cylindrical mold into a ring shape to a first set thickness, and then the prefabricated flexible winding is placed on the surface of the wound base strip. The length direction of the prefabricated flexible winding is not perpendicular to the axis direction of the cylindrical mold. This section of the prefabricated flexible winding is the first section of the winding.

[0060] Continue to wind the base strip to a second set thickness to fix the first winding section, then fold the prefabricated flexible winding to form a ring coil with the first winding section, and use the winding section that forms the ring coil with the first winding section after folding as the second winding section, and then continue to wind the base strip to a second set thickness to fix the second winding section, such as Fig. 9 As shown, the double-dotted line in the figure is the folding line. Repeatedly folding the prefabricated flexible winding and winding the base strip to form multiple coaxial annular coils arranged radially along the cylindrical mold to obtain a tile-shaped laminated structure magnetic component.

[0061] The first winding section and the second winding section are connected end to end to form an S-shaped structure, and a plurality of annular coils distributed radially along the cylindrical mold are formed by continuously folding a strip-shaped prefabricated flexible winding.

[0062] Furthermore, multiple strip-shaped prefabricated flexible windings are evenly distributed around the axis of the cylindrical mold for folding and winding, thereby obtaining multiple tile-shaped laminated magnetic components. That is, multiple coaxial annular coils arranged radially along the cylindrical mold are grouped as one, and multiple groups of annular coils are evenly distributed around the axis of the cylindrical mold.

[0063] Specifically, first, several layers of base strip are wound on the surface of a cylindrical mold to reach a first set thickness, and then a continuous S-shaped pre-strip flexible winding is placed at a certain angle to the winding direction, such as Fig. 9 As shown; it should be noted that in order to ensure the integrity of the end face of the final wound part, the base strip needs to wrap around one end face of the coil in each layer, and wrap around the other end face at a certain angle in the next layer, so that both end faces of the final wound part are firmly wrapped by the base strip. After that, several layers of base strip are wound on the surface of the winding to reach the second set thickness. The wrapped flexible winding is the first section of the winding; then the flexible winding is folded according to the prefabricated fold line. Finally, the flexible winding is completely folded to the surface of the base strip. This section of the winding is the second section of the winding, so that it forms a complete concentric coil with the first section of the winding folded before, as shown Fig. 9 As shown, several layers of base strip are wound on the surface of the winding. Repeat the above manufacturing process, that is, fold repeatedly in a predetermined folding direction, and finally form a complete concentric coil in the folding direction, as shown in FIG. Fig.12 As shown, the continuous S-shaped prefabricated flexible winding is finally formed to form a concentric coil with a certain total thickness and number of turns in the radial direction, and overlaps with the base strip layer by layer, having good integrity, such as Fig.11 shown.

[0064] In this embodiment, four concentric coils are evenly distributed in the annular direction, and their winding diagram is as follows: Fig.11 As shown, the folding and winding diagram on the base strip is as follows Fig.10 shown.

[0065] In specific implementation, since the strip-type prefabricated flexible winding is relatively thin, a thinner base strip is required for winding. Before winding, the surface of the base strip in contact with the strip-type prefabricated flexible winding is first polished until it is relatively smooth, and a layer of glue is evenly applied on the polished surface. The strip-type prefabricated flexible winding, which constitutes about half of the concentric coil, i.e., the first section of the winding, is evenly laid on the surface of the base strip coated with glue, and the designed number is evenly placed around the axis of the cylindrical mold according to the needs; then the base strip is wound to the second set thickness. After the winding is completed, it is polished and glue is evenly applied, and then the strip-type prefabricated flexible winding is folded and evenly laid so that the second section of the winding and the first section of the winding form a ring coil, and finally the base strip is wrapped to the second set thickness. Repeat the above steps of polishing, gluing, folding, and winding the base strip until the required total thickness is reached to obtain the required magnetic element. Finally, glass cloth of appropriate size is filled in the gaps of magnetic component lead wires, lead components, lead pressure plates, etc., and the whole is RTM-infused with resin, cured, and the outer surface is machined to ensure concentricity and surface finish.

[0066] Based on the slotless magnetic component manufacturing method provided in this embodiment, a slotless magnetic component is proposed, which is manufactured using the above-mentioned slotless magnetic component manufacturing method, and includes a base structure and a winding; the base structure is formed by winding a base strip, and the winding is wrapped and fixed inside during the winding process.

[0067] When manufacturing slotless magnetic components with concentric windings, the rotating components have high requirements for dynamic balancing accuracy, so each concentric coil needs to have good quality and shape consistency. In order to ensure the uniformity of the rotor mass distribution after molding, multiple coils need to be evenly distributed in the matrix structure, and fully form an integrated structure with the matrix structure during the process formation process, thereby enhancing the structural strength of the magnetic component components and making the motor last longer.

[0068] The manufacturing method of the slotless magnetic component provided in this embodiment adopts winding technology, which can make the modulus of the finished component far better than the modulus of the material. When the components are formed and assembled using traditional methods, the insulating coating will be uneven, missing, worn or even damaged due to assembly stress and surface friction. In the flexible winding process, the insulating dressing can be better uniformly present in the finished component, which can be achieved through process visualization, winding tension and temperature control. The base strip is selected according to needs, such as resin glue and glass fiber layer, mica tape, etc., and the winding layer matched with the winding needs to ensure insulation.

[0069] The slotless magnetic element manufacturing method provided in this embodiment adopts winding for processing. Firstly, in order to normalize the process assembly, the traditional stator structure is composed of glass fiber, glue layer, winding layer, silicon steel sheet and casing from the inside to the outside. During assembly, a series of means such as interference fit, bolt pin connection, glue filling, molding and the like are required. The winding method can realize the stator assembly and reduce the defects caused by various other assembly processes, such as bubbles, gaps and stress relaxation, etc., so that the winding and the base structure are integrated; secondly, in order to better adjust the mechanical parameters of the structural parts according to actual needs, so that the density, modulus, strength and other properties of the structure after winding molding can be controlled.

[0070] The slotless magnetic component manufacturing method provided in this embodiment can prefabricate both the thin-strip prefabricated flexible winding and the base structure, without the need for traditional processes such as wire embedding, stamping, and pouring. The manufacture of magnetic components such as motor stators and rotors can be realized by using equipment such as winding machines. It has the characteristics of simple equipment, fewer steps, easy molding, and compact structure. It can better realize the integration of the conductor and the base structure, increase the overall structural strength and rigidity of the magnetic component, simplify the lead structure, and enhance the interlayer insulation.

[0071] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for manufacturing a slotless magnetic element, characterized in that: The steps include: The base strip is wound into a ring shape on the surface of a cylindrical mold to a first set thickness, and then the prefabricated winding is placed on the surface of the base strip. Finally, the base strip is continued to be wound to a second set thickness to fix the prefabricated winding.

2. The method for manufacturing a slotless magnetic component according to claim 1, characterized in that: The material of the base strip is one or more of a composite material, an insulating material or a metal material, and the material of the base strip in contact with the prefabricated winding is an insulating material.

3. The method for manufacturing a slotless magnetic component according to claim 2, characterized in that: The composite material is carbon fiber T300, the insulating material is insulating mica, and the metal material is silicon steel.

4. The method for manufacturing a slotless magnetic component according to claim 1, characterized in that: When making the slotless magnetic element of the wave winding, the base strip is wound on the surface of the cylindrical mold to a first set thickness, and then the prefabricated winding is placed on the surface of the base strip. The base strip is then inserted into the annular hole along the length direction of the prefabricated winding and wound, and finally the base strip is continued to be wound to a second set thickness to fix the prefabricated winding.

5. The method for manufacturing a slotless magnetic component according to claim 1, characterized in that: When making a slotless magnetic component of a stacked winding, the base strip is wound on the surface of a cylindrical mold to a first set thickness, then the prefabricated winding is placed on the surface of the base strip and wound around the axis of the cylindrical mold, and finally the base strip is wound to a second set thickness to fix the prefabricated winding.

6. The method for manufacturing a slotless magnetic component according to claim 1, characterized in that: When manufacturing the slotless magnetic components of the concentric winding, the prefabricated winding is set as a continuous S-shaped belt-type prefabricated flexible winding; The base strip is wound on the surface of the cylindrical mold into a ring shape to a first set thickness, and then the prefabricated flexible winding is placed on the surface of the wound base strip, the length direction of the prefabricated flexible winding is not perpendicular to the axis direction of the cylindrical mold, and this section of the prefabricated flexible winding is the first section of the winding; Continue to wind the base strip to a second set thickness to fix the first winding section, then fold the prefabricated flexible winding to form a ring coil with the first winding section, and take the winding section that forms the ring coil with the first winding section after folding as the second winding section, and then continue to wind the base strip to a second set thickness to fix the second winding section; The first winding section and the second winding section are connected end to end to form an S-shaped structure.

7. The method for manufacturing a slotless magnetic component according to claim 6, characterized in that: The prefabricated flexible winding is repeatedly folded and the base strip is wound to form a plurality of coaxial annular coils arranged radially along the cylindrical mold.

8. The method for manufacturing a slotless magnetic component according to claim 7, characterized in that: A plurality of annular coils distributed radially along the cylindrical mold are formed by continuously folding a strip-shaped prefabricated flexible winding.

9. The method for manufacturing a slotless magnetic component according to claim 8, characterized in that: A plurality of coaxial annular coils arranged radially along the cylindrical mold is formed into a group, and the plurality of groups of annular coils are evenly distributed around the axis of the cylindrical mold.

10. A slotless magnetic component, manufactured by the slotless magnetic component manufacturing method according to any one of claims 1 to 9, characterized in that: The invention comprises a base structure and a winding; the base structure is formed by winding a base strip, and the winding is wrapped and fixed inside during the winding process.

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