Cogging-free motor stator winding tool and use method thereof

Abstract

The invention relates to a cogging-free motor stator winding tool and a use method thereof. The cogging-free motor stator winding tool comprises a flat plate, a pin, a shaping mandrel, a shaping clamp and a locking device. Two rows of parallel and symmetrical pin holes are formed in the upper end face of the flat plate, pins are inserted into the pin holes, every two adjacent columns of pins are used for supporting a rectangular coil, and one or more layers of transversely arranged rectangular coils are arranged through the two rows of pins to form a linear winding; the outer circular vertical surface of the shaping mandrel is used for shaping a linear winding into an arc-shaped winding, the shaping hoop is coaxially clamped outside the shaping mandrel, and the inner circular vertical surface of the shaping hoop clings to the outer end surface of the linear winding and is locked by the locking device to press and shape the arc-shaped winding. According to the invention, the coil position can be accurately positioned, the relative position between the coils can be restrained, the processing difficulty of the gullet-free motor stator is reduced, the processing period of the gullet-free motor stator is shortened, the winding tool is simple in structure, and the use method is convenient to operate.

Description

Technical Field

[0001] The invention relates to the technical field of motor stator processing, and in particular to a slotless motor stator winding winding tool and a use method thereof. Background Art

[0002] The brushless motor stator adopts a slotless structure. Compared with the slotted motor structure, it can overcome the defects of the slotted structure, expand the distribution space of the coil winding, and make the motor run more smoothly, with low running noise and more reliable working performance. When winding the motor stator with a slotted structure, one method is to directly wind the enameled wire in the slots of the stator core; the other method is to first wind the hollow coil and then embed the hollow coil in the slot. For the slotless structure, since the core does not have a coil positioning groove, it is difficult to determine the position of the coil along the circumference of the stator core, and the relative position relationship between the coils lacks constraints, which affects the running stability and performance of the motor. At the same time, the slotless motor stator is more difficult to process than the slotted motor stator, and the processing cycle is extended.

[0003] In view of the above technical problems, a slotless motor stator winding winding tool and a use method thereof are proposed. Summary of the invention

[0004] The purpose of the present invention is to overcome the shortcomings of the prior art and provide a slotless motor stator winding tooling that can accurately locate the coil position, constrain the relative position between the coils, reduce the difficulty of slotless motor stator processing, and shorten the slotless motor stator processing cycle.

[0005] The present invention also provides a method for using a winding tool for a slotless motor stator winding. The winding tool has a simple structure and the method for using is easy to operate.

[0006] The present invention solves the technical problem by the following technical solutions:

[0007] A slotless motor stator winding tool, comprising a flat plate, a pin, a shaping mandrel, a shaping clamp and a locking device;

[0008] The upper end surface of the plate is provided with two rows of parallel and symmetrical pin holes, each of which is inserted with a pin. Two adjacent rows of pins are used to support a rectangular coil. One or more layers of transversely arranged rectangular coils are arranged through the two rows of pins to form a linear winding.

[0009] The outer circular vertical surface of the shaping mandrel is used to shape the linear winding into an arc winding. The shaping clamp is coaxially clamped outside the shaping mandrel, and the inner circular vertical surface is tightly attached to the outer end surface of the linear winding and locked by a locking device to compress and shape the arc winding.

[0010] Furthermore, a bottom plate is formed at the lower end of the shaping mandrel, and the linear winding is clamped on the bottom plate.

[0011] Furthermore, the number of the pin holes and the number of the pins are both odd.

[0012] Furthermore, the shaping clamp is composed of four circular arcs, which are assembled into a circular shaping clamp through a locking device.

[0013] Furthermore, the locking device consists of a screw and a nut.

[0014] A method for using a slotless motor stator winding tool comprises the following steps:

[0015] S1. Make a straight winding:

[0016] S1.1 Insert the pin into the pin hole of the plate;

[0017] S1.2 Place the rectangular coil on the pins, with a pin at each of the four inner corners to hold the rectangular coil open;

[0018] S1.3 Place the rectangular coils regularly on the flat plate as specified in the motor design drawing;

[0019] S1.4 Acetal glue is applied on the rectangular coil, and after the glue is cured, adjacent rectangular coils are bonded together to form a linear winding;

[0020] S2. Making arc winding:

[0021] S2.1 Remove the linear winding made in S1 from the pin;

[0022] S2.2 Apply a proper amount of alcohol on the linear winding to make the acetal glue slightly sticky, and then wind the linear winding around the outer circle of the shaping mandrel;

[0023] S2.3 Use the inner circle of the shaped clamp to fit tightly against the outer end face of the winding and lock it with a locking device;

[0024] S2.4 After the acetal glue is cured, an arc winding is made;

[0025] S3. Making slotless motor stator:

[0026] S3.1 Bond the arc winding to the inner circle of the core;

[0027] S3.2 is potting performed to obtain a slotless motor stator.

[0028] The advantages and positive effects of the present invention are:

[0029] 1. The stator winding tooling of the slotless motor of the present invention comprises two rows of parallel and symmetrical pin holes on the upper end surface of the flat plate, pins are inserted into the pin holes, two adjacent rows of pins are used to support a rectangular coil, one or more layers of transversely arranged rectangular coils are arranged by two rows of pins to form a linear winding; the position of the rectangular coil can be accurately defined and the rectangular coil can be fixed.

[0030] 2. The stator winding tooling of the slotless motor of the present invention, the outer cylindrical surface of the shaping mandrel is used to shape the linear winding into an arc winding, the shaping clamp is coaxially clamped outside the shaping mandrel, and the inner cylindrical surface is tightly attached to the outer end surface of the linear winding, and is locked by a locking device to compress and shape the arc winding. The lower end of the shaping mandrel is formed with a bottom plate, and the linear winding is clamped on the bottom plate.

[0031] 3. The slotless motor stator winding tooling and the use method of the present invention can accurately locate the rectangular coil position, constrain the relative position between the rectangular coils, reduce the difficulty of slotless motor stator processing, shorten the slotless motor stator processing cycle, and the winding tooling has a simple structure and is easy to operate. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 A partial cross-sectional perspective view of a tooling for winding stator windings of a slotless motor;

[0033] Figure 2 A schematic diagram of a linear winding arrangement of a slotless motor stator winding winding tool;

[0034] Figure 3 A schematic diagram of a linear winding of a slotless motor stator winding winding tool;

[0035] Figure 4 A schematic diagram of an arc winding of a slotless motor stator winding winding tool;

[0036] Figure 5 It is a schematic diagram of the stator of a slotless motor;

[0037] In the figure:

[0038] 1- flat plate, 2- pin hole, 3- pin, 4- shaping mandrel, 5- shaping clamp, 6- locking device, 7- straight winding, 8- arc winding, 9- slotless motor stator, 10- rectangular coil, 11- bottom plate. DETAILED DESCRIPTION

[0039] The present invention is further described in detail below through specific examples. The following examples are only illustrative and not restrictive, and the protection scope of the present invention cannot be limited thereto.

[0040] A tool for winding the stator winding of a slotless motor, comprising a plate 1, a pin 3, a shaping mandrel 4, a shaping clamp 5 and a locking device 6; the upper end surface of the plate 1 is formed with two rows of parallel and symmetrical pin holes 2, and the pin holes 2 are all inserted with pins 3, and two adjacent rows of pins 3 are used to support a rectangular coil 10, and one or more layers of transversely arranged rectangular coils 10 are arranged through two rows of pins 3 to form a linear winding 7; the outer circular vertical surface of the shaping mandrel 4 is used to shape the linear winding 7 into an arc winding 8, and the shaping clamp 5 is coaxially clamped outside the shaping mandrel 4, and the inner circular vertical surface is tightly attached to the outer end surface of the linear winding 7, and is locked by the locking device 6 to compress and shape the arc winding 8. The lower end of the shaping mandrel 4 is formed with a bottom plate 11, and the linear winding 7 is clamped on the bottom plate 11. The pin holes 2 and pins 3 are both odd numbers. The shaping clamp 5 is composed of four arcs, which are assembled into a circular shaping clamp 5 by a locking device 6. The locking device 6 is composed of a screw and a nut. The present invention can accurately locate the coil position, bind the relative position between the coils, reduce the processing difficulty of the slotless motor stator 9, shorten the processing cycle of the slotless motor stator 9, and its winding tooling structure is simple and the use method is easy to operate.

[0041] The inner circumference C of the core is calculated according to the inner diameter R of the stator core; the inner circumference C of the core is divided by the number n of rectangular coils 10 of the motor to obtain the distance L between adjacent rectangular coils 10. The linear winding 7 is manufactured according to the inner circumference C of the core, the distance L between adjacent rectangular coils 10 and the internal size parameters (a, b) of the rectangular coil 10.

[0042] The distance between two rows of pin holes 2 is the internal dimension parameter b of the rectangular coil 10. There are two types of distances between pin holes 2 in the same row: one is the size of the rectangular coil 10, which is the internal dimension parameter a of the rectangular coil 10; the other is the distance L between adjacent rectangular coils 10.

[0043] The linear winding 7 cannot be placed directly on the inner circle of the stator core, and needs to be shaped into an arc for subsequent bonding. The shaping mandrel 4 is made according to the inner circle size of the motor stator, and the outer diameter of the shaping mandrel 4 is larger than the inner circle size of the stator. The shaping clamp 5 is made according to the inner circle size of the core, and the inner circle size of the shaping clamp 5 is smaller than the inner circle size of the core.

[0044] Working principle of the present invention:

[0045] Pins 3 are inserted into two rows of parallel and symmetrical pin holes 2 formed at the upper end of the flat plate 1; the rectangular coil 10 is placed at the pins 3, and there is a pin 3 at each of the four inner corners to support the rectangular coil 10; according to the requirements of the motor design drawing, the rectangular coil 10 is placed in two layers in a regular overlapping manner on the flat plate 1, so that the position of the rectangular coil 10 is fixed and the accurate position definition of the rectangular coil 10 is obtained; acetal glue is applied on the rectangular coil 10, and after the glue is cured, the adjacent rectangular coils 10 are bonded together to form a linear winding 7; the prepared linear winding 7 is removed from the pins 3; an appropriate amount of alcohol is applied to the linear winding 7 to make the acetal glue slightly sticky, and then the linear winding 7 is wound around the outer circle of the shaping core shaft 4 and mounted on the bottom plate 11; the inner circle of the shaping clamp 5 is pressed against the outer end face of the winding and locked by the locking device 6; after the acetal glue is cured, an arc winding 8 is formed; the arc winding 8 is bonded to the inner circle of the iron core; potting is performed to obtain a slotless motor stator 9.

[0046] A method for using a slotless motor stator winding tool comprises the following steps:

[0047] S1. Making a linear winding 7:

[0048] S1.1 Insert the pin 3 into the pin hole of the plate 1;

[0049] S1.2 Place the rectangular coil 10 at the pins 3, with a pin 3 at each of the four inner corners to prop up the rectangular coil 10;

[0050] S1.3 According to the requirements of the motor design drawing, the rectangular coil 10 is placed in two layers in a regular overlapping manner on the flat plate 1;

[0051] S1.4 Acetal glue is applied on the rectangular coil 10, and after the glue is cured, adjacent rectangular coils 10 are bonded together to form a linear winding 7;

[0052] S2. Making arc winding 8:

[0053] S2.1 Remove the linear winding 7 made in S1 from the pin 3;

[0054] S2.2 Apply a proper amount of alcohol on the linear winding 7 to make the acetal glue slightly sticky, and then wind the linear winding 7 around the outer circle of the shaping mandrel 4;

[0055] S2.3 Use the inner circle of the shaping clamp 5 to fit tightly against the outer end surface of the winding and lock it with the locking device 6;

[0056] S2.4 After the acetal adhesive is cured, an arc winding 8 is formed;

[0057] S3. Manufacturing slotless motor stator 9:

[0058] S3.1 bonding the arc winding 8 to the inner circle of the core;

[0059] S3.2 performs potting to obtain the slotless motor stator 9.

[0060] Although the embodiments and drawings of the present invention are disclosed for illustrative purposes, those skilled in the art will appreciate that various substitutions, changes and modifications are possible without departing from the spirit and scope of the present invention and the appended claims. Therefore, the scope of the present invention is not limited to the contents disclosed in the embodiments and drawings.

Claims

1. A tool for winding stator windings of a slotless motor, characterized in that: It comprises a flat plate (1), a pin (3), a shaping mandrel (4), a shaping clamp (5) and a locking device (6); The upper end surface of the plate (1) is provided with two rows of parallel and symmetrical pin holes (2), each of which is inserted with a pin (3), and two adjacent rows of pins (3) are used to support a rectangular coil (10), and one or more layers of transversely arranged rectangular coils (10) are arranged through the two rows of pins (3) to form a linear winding (7); The outer circular vertical surface of the shaping mandrel (4) is used to shape the linear winding (7) into an arc-shaped winding (8), and the shaping clamp (5) is coaxially clamped on the outside of the shaping mandrel (4), while the inner circular vertical surface is tightly attached to the outer end surface of the linear winding (7) and is locked by a locking device (6) to compress and shape the arc-shaped winding (8).

2. The slotless motor stator winding winding tool according to claim 1, characterized in that: The lower end of the shaping mandrel (4) is provided with a bottom plate (11), and the linear winding (7) is clamped on the bottom plate (11).

3. The slotless motor stator winding winding tool according to claim 1, characterized in that: The pin holes (2) and pins (3) are both in odd numbers.

4. The slotless motor stator winding winding tool according to claim 1, characterized in that: The shaping clamp (5) is composed of four circular arcs, which are assembled into a circular shaping clamp (5) through a locking device (6).

5. The slotless motor stator winding tool according to claim 1, characterized in that: The locking device (6) consists of a screw and a nut.

6. A method for using the slotless motor stator winding tool according to claim 1, characterized in that: The following steps are involved: S1. Make a straight winding: S1.1 Insert the pin into the pin hole of the plate; S1.2 Place the rectangular coil on the pins, with a pin at each of the four inner corners to hold the rectangular coil open; S1.3 Place the rectangular coils regularly on the flat plate as specified in the motor design drawing; S1.4 Acetal glue is applied on the rectangular coil, and after the glue is cured, adjacent rectangular coils are bonded together to form a linear winding; S2. Making arc winding: S2.1 Remove the linear winding made in S1 from the pin; S2.2 Apply a proper amount of alcohol on the linear winding to make the acetal glue slightly sticky, and then wind the linear winding around the outer circle of the shaping mandrel; S2.3 Use the inner circle of the shaped clamp to fit tightly against the outer end face of the winding and lock it with a locking device; S2.4 After the acetal glue is cured, an arc winding is made; S3. Making slotless motor stator: S3.1 Bond the arc winding to the inner circle of the core; S3.2 is potting performed to obtain a slotless motor stator.

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