An assembled high-energy-density frameless motor

Abstract

The application belongs to the technical field of electric machines, and particularly relates to a high-energy-density frameless motor of assembled type, which comprises a stator and a rotor; the stator drives the rotor to rotate through electromagnetic action, and the stator comprises a plurality of winding assembly units; each winding assembly unit is assembled into a whole through a fixing device; the fixing device comprises a connecting assembly and a plug assembly; the connecting assembly is arranged in the circumferential direction of the stator, and the plug assembly can be coupled and connected with the connecting assembly through each winding assembly unit to fix each winding assembly unit. The plurality of winding assembly units are assembled into a whole through the fixing device, each winding assembly unit is separately wound, the number of winding turns of the enameled wire group can be increased, the energy density is increased, the problems of low winding precision, insufficient number of winding turns of the enameled wire, low filling rate, and small energy density of the frameless motor caused by directly and continuously winding the enameled wire on the core frame are solved.

Description

Technical Field

[0001] This invention belongs to the field of motor technology, and particularly relates to an assembled high-energy-density frameless motor. Background Technology

[0002] An electric motor, commonly known as a "motor," is an electromagnetic device that converts or transmits electrical energy based on the law of electromagnetic induction. It includes framed motors and frameless motors. Among them, the frameless motor is a new type of torque motor. Because it eliminates the casing of the traditional motor, it has the advantages of small size, light weight, low inertia, compact structure, and high power. It has strong adaptability and is mainly used in robot joints, medical robots, sensor universal joints, drone propulsion and guidance systems, and other fields.

[0003] Existing frameless motors, such as the high-torque frameless motor for humanoid robots disclosed in CN117856527B, include a frameless motor, a fixing mechanism, and a reduction mechanism. The input end of the reduction mechanism is connected to the output end of the frameless motor, and the output end of the reduction mechanism is connected to the fixing mechanism. The motor is an internal rotor frameless motor, including a stator with a limit frame fixedly mounted on it. A rotor coaxial with the stator is rotatably mounted inside the stator. The reduction mechanism includes a drive wheel, a transmission chain, a driven wheel, and a gear ring. The drive wheel is elliptical and fixedly mounted on the rotor. By mounting a drive wheel on the rotor of the internal rotor frameless motor and connecting the rotor to the driven wheel and the fixing structure via bearings, the fixing mechanism can fix the driven wheel to the input shaft of the load. The transmission chain meshes with the drive wheel and the driven wheel to achieve speed reduction, thereby reducing the rotational speed and increasing the motor torque.

[0004] The existing frameless motors have low energy density, which does not meet the requirements of motors in robots. Therefore, it is necessary to increase the energy density, that is, to increase the winding of enameled wire groups. The existing frameless motors are wound directly and continuously on the iron core frame. Domestic winding machines are not precise enough in continuous winding, the number of enameled wire groups is insufficient, and the filling rate is insufficient, resulting in low energy density of frameless motors. Summary of the Invention

[0005] The purpose of this invention is to provide an assembled high-energy-density frameless motor, which aims to solve the technical problem of low energy density in existing frameless motors.

[0006] To achieve the above objectives, this invention provides a modular high-energy-density frameless motor, comprising a stator and a rotor; the stator drives the rotor to rotate via electromagnetic action, and the stator includes multiple winding assembly units; each winding assembly unit is assembled and surrounded into a whole by a fixing device, the fixing device including a connecting component and a lamination component; the connecting component is arranged circumferentially around the stator, and the lamination component can pass through each winding assembly unit and couple with the connecting component to fix each winding assembly unit.

[0007] Optionally, each winding assembly unit includes a wire frame and an enameled wire assembly; the enameled wire assembly is wound on the wire frame, the wire frame has an "I" shaped structure, and the wire frame includes an inwardly recessed winding portion; the enameled wire assembly is wound on the winding portion, and the wire frame has an insert channel in the middle, the insert channel being used for the insert assembly to pass through.

[0008] Optionally, the connecting assembly is formed by stacking multiple sets of connecting pieces, each set of connecting pieces including a combined circular piece and multiple combined single pieces; the multiple combined single pieces are evenly disposed on the combined circular piece, and multiple first grooves are provided on the combined circular piece, each first groove is disposed between two combined single pieces, and an insertion gap is also formed between the two combined single pieces, and at least one first positioning hole is provided between two first grooves, and at least one second positioning hole is provided on each combined single piece, and the number of second positioning holes in each set of connecting pieces is the same as the number of first positioning holes.

[0009] Optionally, the insert assembly includes multiple sets of insert components; each set of insert components includes long inserts and short inserts; the long inserts and the short inserts are stacked vertically, and each long insert and the short insert is provided with a functional connection point; each winding assembly unit can have multiple sets of insert components inserted through it, and each set of insert components passes through the insert channel and connects to the connecting piece; each set of insert components has a corresponding third positioning hole on each long insert and the short insert.

[0010] Optionally, the number of insert pieces inserted into each winding assembly unit corresponds to the number of connecting pieces. The long insert pieces in each group of insert pieces can be inserted into the corresponding insertion gap and connected to the connecting piece. The short insert pieces in each group of insert pieces can abut against the side wall of the corresponding combined circular piece and connect to the connecting piece. Each long insert piece is provided with a second groove. After each long insert piece is inserted into the corresponding insertion gap, the multiple first grooves and multiple second grooves provided vertically can form a groove channel.

[0011] Optionally, the winding part has a first blocking part and a second blocking part at both ends. The first blocking part has two protrusions symmetrically arranged on it. The two protrusions are located on both sides of the insert channel. Each protrusion has a third groove, which is located corresponding to the position of the groove channel. Each insert channel has glue inlet grooves on its upper and lower sides. One end of each glue inlet groove is connected to the third groove, and the other end extends to the third positioning hole.

[0012] Optionally, the multiple first positioning holes and multiple second positioning holes corresponding to each other can be sealed and reinforced with glue, the multiple third positioning holes corresponding to each other can be sealed and reinforced with glue, and the two third grooves and the corresponding groove channels in the same wire frame can be welded.

[0013] Optionally, the plurality of first positioning holes and the plurality of second positioning holes corresponding to each other can be fixed by inserting a metal shaft, and the plurality of third positioning holes corresponding to each other can be sealed and reinforced with glue.

[0014] Optionally, the frameless motor has an internal rotor structure, with the rotor coaxially disposed inside the stator, and the rotor including a rotor core; multiple permanent magnets are fixed on the outer ring surface of the rotor core.

[0015] Optionally, the frameless motor has an external rotor structure, the stator is coaxially placed inside the rotor, and the rotor includes a rotor core; multiple permanent magnets are fixed on the inner ring surface of the rotor core.

[0016] Compared with the prior art, the above-mentioned one or more technical solutions in the assembled high-energy-density frameless motor provided in the embodiments of the present invention have at least one of the following technical effects:

[0017] Multiple winding assembly units are assembled into a whole by fixing devices. Each winding assembly unit is wound separately, which can increase the number of winding coils of enameled wire and increase energy density. This solves the problems of low winding accuracy, insufficient number of winding groups of enameled wire, low filling rate, and low energy density of frameless motors caused by traditional continuous winding directly on the iron core frame. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the structure of the present invention.

[0020] Figure 2 This is a schematic diagram of the connecting piece structure of the present invention.

[0021] Figure 3 This is a partial structural diagram of the present invention.

[0022] Figure 4 This is a partial structural diagram of the present invention.

[0023] Figure 5 This is a schematic diagram of the insert structure of the present invention.

[0024] Figure 6 This is a schematic diagram of the wireframe structure of the present invention.

[0025] Figure 7 This is a schematic diagram of the internal rotor structure in Embodiment 1 of the present invention.

[0026] Figure 8 This is a schematic diagram of the external rotor structure in Embodiment 2 of the present invention.

[0027] The following are the labeling elements in the figure:

[0028] 100. Stator; 110. Winding assembly unit; 111. Wire frame; 1111. Winding section; 1112. First blocking section; 1113. Second blocking section; 1114. Lug; 1115. Third groove; 1116. Glue groove; 1117. Insert channel; 112. Enamelled wire assembly; 120. Connecting piece; 121. Combined round piece; 122. Combined single piece; 123. First groove; 124. Insertion gap; 125. First positioning hole; 126. Second positioning hole; 130. Insert piece; 131. Long insert; 1311. Second groove; 132. Short insert; 133. Functional connection point; 134. Third positioning hole; 140. Groove channel;

[0029] 200, Rotor; 210, Rotor core; 220, Permanent magnet. Detailed Implementation

[0030] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain embodiments of the present invention, and should not be construed as limiting the present invention.

[0031] In the description of the embodiments of the present invention, it should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the embodiments of the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention.

[0032] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of embodiments of the present invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0033] In the embodiments of the present invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of the present invention according to the specific circumstances.

[0034] Example 1

[0035] according to Figure 1-7 As shown, it includes a stator 100 and a rotor 200; the stator 100 drives the rotor 200 to rotate through electromagnetic action. The stator 100 includes multiple winding assembly units 110; each winding assembly unit 110 is assembled and surrounded into a whole by a fixing device, which includes a connecting component and a lamination component; the connecting component is arranged circumferentially around the stator 100, and the lamination component can pass through each winding assembly unit 110 and be coupled to the connecting component to fix each winding assembly unit 110.

[0036] Specifically, multiple winding assembly units 110 are assembled into a whole using a fixing device. Each winding assembly unit 110 is wound individually, which increases the number of winding coils in the enameled wire group 112 and increases the energy density. This solves the problems of low winding accuracy, insufficient number of enameled wire winding groups, low filler ratio, and low energy density of frameless motors caused by traditional continuous winding directly on the iron core frame. By setting up connecting components and insert components to assemble the winding assembly units 110 with high filler ratio, the structure is stable and has high strength.

[0037] Furthermore, traditional modular stators 100 mostly use snap-fit ​​assembly, and the winding method is still to wind multiple groups of wires and then assemble them. The energy density of the winding is low, and it is not possible to wind individual winding units and then assemble them.

[0038] according to Figure 1 and 6 As shown, each winding assembly unit 110 includes a wire frame 111 and an enameled wire assembly 112; the enameled wire assembly 112 is wound on the wire frame 111, the wire frame 111 has an "I" shaped structure, the wire frame 111 includes an inwardly recessed winding portion 1111; the enameled wire assembly 112 is wound on the winding portion 1111, and the wire frame 111 has an insert channel 1117 in the middle, the insert channel 1117 is used for insert assemblies to pass through.

[0039] Specifically, the "I"-shaped structure is stable and easier to wind. The inwardly recessed winding section provides space for the enameled wire assembly 112 to be wound. At the same time, the high winding precision, tight and neat arrangement, and high fill rate result in a high energy density of a single coil. The wire frame 111 has a hollow center with a slotted channel 1117 for the slotted assembly to pass through. Understandably, the slotted assembly is large at one end and small at the other. The smaller end can pass through the slotted channel 1117, while the larger end is limited and locked to prevent the wound enameled wire assembly 112 from falling off the wire frame 111.

[0040] according to Figure 2-4 As shown, the insert assembly includes multiple long inserts 131 and multiple short inserts 132; each winding assembly unit 110 can be stacked vertically with multiple long inserts 131 and multiple short inserts 132 passing through it, and each long insert 131 and each short insert 132 passes through the insert channel 1117 and is connected to the connecting assembly. The connecting assembly is constructed by stacking multiple layers of combined circular pieces 121 and multiple layers of combined pieces, each layer of combined pieces including multiple combined single pieces 122, with insertion gaps formed between each combined single piece 122.

[0041] Specifically, the combination discs 121 and combination pieces can be arranged in an alternating pattern. For example, a layer of combination discs 121 followed by a layer of combination pieces is preferred, or two layers of combination discs 121 followed by a layer of combination pieces can be used in this cycle, or one layer of combination discs 121 followed by two layers of combination pieces can be used in this cycle, all of which are within the scope of protection of this invention. It is understood that the long insert 131 is used to insert into the combination pieces for connection, and the short insert 132 is used to abut against the combination discs 121 for connection. This corresponds to different combinations of long inserts 131 and short inserts 132, such as one long insert 131 and one short insert 132 in a cycle, two long inserts 131 and one short insert 132 in a cycle, one long insert 131 and two short inserts 132 in a cycle, and many other combinations. The combinations of the insertion components and the connection components correspond to each other.

[0042] according to Figure 2-4 As shown, the connecting assembly is formed by stacking multiple sets of connecting pieces 120. Each set of connecting pieces 120 includes a combined circular piece 121 and multiple combined single pieces 122. The multiple combined single pieces 122 are evenly disposed on the combined circular piece 121. Multiple first grooves 123 are provided on the combined circular piece 121. Each first groove 123 is disposed between two combined single pieces 122, and an insertion gap 124 is also formed between the two combined single pieces 122. At least one first positioning hole 125 is provided between two first grooves 123. At least one second positioning hole 126 is provided on each combined single piece 122. The number of second positioning holes 126 in each set of connecting pieces 120 is the same as the number of first positioning holes 125.

[0043] Specifically, in each set of connecting pieces 120, the combined circular piece 121 is at the bottom, and multiple combined individual pieces 122 are disposed on the combined circular piece 121. Multiple sets of connecting pieces 120 are stacked sequentially to form a connecting assembly. There are two first positioning holes 125 between the two first grooves 123, and correspondingly, there are also two second positioning holes 126 in each combined individual piece 122. The functions of the first positioning holes 125 and the second positioning holes 126 are for installation positioning and sealing with adhesive.

[0044] according to Figure 3-6As shown, the insert assembly includes multiple sets of insert components 130; each set of insert components 130 includes a long insert 131 and a short insert 132; the long insert 131 and the short insert 132 are stacked and connected vertically, and both the long insert 131 and the short insert 132 are provided with functional connection points 133; each winding assembly unit 110 can be fitted with multiple sets of insert components 130, and each set of insert components 130 passes through the insert channel 1117 and is connected to the connecting piece 120; each set of insert components 130 has a corresponding third positioning hole 134 on the long insert 131 and the short insert 132. The number of insert pieces 130 inserted into each winding assembly unit 110 corresponds to the number of connecting pieces 120. The long insert pieces 131 in each group of insert pieces 130 can be inserted into the corresponding insertion gap 124 and connected to the connecting piece 120. The short insert pieces 132 in each group of insert pieces 130 can abut against the side wall of the corresponding combined circular piece 121 and connect to the connecting piece 120. Each long insert piece 131 is provided with a second groove 1311. After each long insert piece 131 is inserted into the corresponding insertion gap 124, the multiple first grooves 123 and multiple second grooves 1311 provided above and below can form a groove channel 140.

[0045] Specifically, each set of insert pieces 130 consists of a short insert piece 132 at the bottom and a long insert piece 131 at the top, stacked together. The insert pieces 130 correspond precisely to the connecting pieces 120. The long insert piece 131 in each set of insert pieces 130 can be inserted into the corresponding insertion gap 124 to connect with the connecting piece 120. The short insert piece 132 in each set of insert pieces 130 can abut against the side wall of the corresponding combined circular piece 121 to connect with the connecting piece 120. Both the long insert piece 131 and the short insert piece 132 have a snap-fit ​​portion at one end, and the other end is shorter than the snap-fit ​​portion, used to pass through the insert channel 1117. The snap-fit ​​portion snaps onto the enameled wire assembly 112. Multiple sets of insert pieces 130 can completely fill the insert channel 1117.

[0046] Furthermore, the third positioning hole 134 serves for installation positioning and sealing with adhesive, and the functional connection point 133 is used for vertical connection between each long insert 131 and each short insert 132.

[0047] according to Figure 6 As shown, the winding part 1111 has a first blocking part 1112 and a second blocking part 1113 at both ends. The first blocking part 1112 has two protrusions 1114 symmetrically arranged on it. The two protrusions 1114 are located on both sides of the insert channel 1117. Each protrusion 1114 has a third groove 1115, which is located at the position of the groove channel 140. Each insert channel 1117 has glue inlet grooves 1116 on its upper and lower sides. One end of each glue inlet groove 1116 is connected to the third groove 1115, and the other end extends to the third positioning hole 134.

[0048] Specifically, the first blocking part 1112 and the second blocking part 1113 are used to prevent the enameled wire assembly 112 from falling off after winding. A third groove 1115 is provided for welding with the groove channel 140, which allows the wire frame 111 and the fixing device to form a whole for connection, resulting in better structural strength. Each insert channel 1117 has glue inlet grooves 1116 on its upper and lower sides, which allow glue to be poured into the third groove 1115 under vacuum conditions. The glue can flow into the third positioning hole 134 through the glue inlet grooves 1116 for sealing.

[0049] according to Figure 1-6 As shown, the multiple first positioning holes 125 and multiple second positioning holes 126 corresponding to the upper and lower parts can be sealed and reinforced with glue, and the multiple third positioning holes 134 corresponding to the upper and lower parts can be sealed and reinforced with glue. The two third grooves 1115 and the corresponding groove channels 140 in the same wire frame 111 can be welded.

[0050] In another embodiment, a plurality of first positioning holes 125 and a plurality of second positioning holes 126 corresponding to the upper and lower parts can be fixed by inserting a metal shaft, and a plurality of third positioning holes 134 corresponding to the upper and lower parts can be sealed and reinforced by potting glue.

[0051] Specifically, the insertion of the metal shaft and the welding treatment on the third groove 1115 and the groove channel 140 are all to increase the connection strength and make the overall strength more robust.

[0052] according to Figure 7 As shown, the frameless motor has an inner rotor 200 structure, which is coaxially disposed inside the stator 100. The rotor 200 includes a rotor core 210; multiple permanent magnets 220 are fixed on the outer ring surface of the rotor core 210. Specifically, the inner rotor 200 structure has high speed, good heat dissipation, and is easy to install.

[0053] Example 2

[0054] according to Figure 8 As shown, the frameless motor has an external rotor structure. The stator 100 is coaxially placed inside the rotor 200, which includes a rotor core 210. Multiple permanent magnets 220 are fixed on the inner ring surface of the rotor core 210. Specifically, the external rotor 200 structure has a large diameter, high torque output, and a compact structure.

[0055] The above description, in conjunction with specific preferred embodiments, provides a further detailed explanation of the present invention and should not be construed as limiting the specific implementation of the invention to these descriptions. For those skilled in the art, the architectural form of this invention can be flexibly varied without departing from its conceptual framework, leading to the derivation of a series of products. Any simple deductions or substitutions should be considered as falling within the patent protection scope defined by the submitted claims.

Claims

1. A modular high-energy-density frameless motor, characterized in that, The system includes a stator and a rotor; the stator drives the rotor to rotate via electromagnetic action, and the stator includes multiple winding assembly units; each winding assembly unit is assembled into a whole by a fixing device, the fixing device including a connecting component and a lamination component; the connecting component is arranged circumferentially around the stator, and the lamination component can pass through each winding assembly unit and couple to the connecting component to fix each winding assembly unit; the connecting component is formed by multiple sets of connecting plates stacked vertically, each set of connecting plates including a combined circular plate and multiple combined single plates; the multiple combined single plates are evenly arranged on the combined circular plate, and the combined circular plate has multiple first grooves, each first groove being located between two combined single plates, forming an insertion gap between the two combined single plates, and at least one first positioning hole being provided between two first grooves, and each combined single plate correspondingly having at least one second positioning hole, the number of second positioning holes in each set of connecting plates being... The number of inserts is consistent with the number of the first positioning holes; the insert assembly includes multiple sets of insert pieces; each set of insert pieces includes long inserts and short inserts; the long inserts and the short inserts are stacked and connected vertically, and each long insert and the short insert is provided with a functional connection point; each winding assembly unit can be provided with multiple sets of insert pieces, and each set of insert pieces passes through the insert channel and connects with the connecting piece; each set of insert pieces has a corresponding third positioning hole on the long insert and the short insert; the number of insert pieces inserted into each winding assembly unit corresponds to the number of connecting pieces, the long insert in each set of insert pieces can be inserted into the corresponding insertion gap and connect with the connecting piece, the short insert in each set of insert pieces can abut against the side wall of the corresponding combined disc and connect with the connecting piece, each long insert is provided with a second groove, and after each long insert is inserted into the corresponding insertion gap, the multiple first grooves and the multiple second grooves provided vertically can form a groove channel.

2. The assembled high-energy-density frameless motor according to claim 1, characterized in that, Each winding assembly unit includes a wire frame and an enameled wire assembly; the enameled wire assembly is wound on the wire frame, the wire frame has an "I" shaped structure, and the wire frame includes an inwardly recessed winding portion; the enameled wire assembly is wound on the winding portion, and the wire frame has an insert channel in the middle, the insert channel being used for the insert assembly to pass through.

3. The assembled high-energy-density frameless motor according to claim 2, characterized in that, The winding part has a first blocking part and a second blocking part at both ends. The first blocking part has two protrusions symmetrically arranged on it. The two protrusions are located on both sides of the insert channel. Each protrusion has a third groove, which is located corresponding to the position of the groove channel. Each insert channel has glue inlet grooves on its upper and lower sides. One end of each glue inlet groove is connected to the third groove, and the other end extends to the third positioning hole.

4. The assembled high-energy-density frameless motor according to claim 3, characterized in that, The multiple first positioning holes and multiple second positioning holes corresponding to each other can be sealed and reinforced with glue, and the multiple third positioning holes corresponding to each other can be sealed and reinforced with glue. The two third grooves and the corresponding groove channels in the same wire frame can be welded.

5. The assembled high-energy-density frameless motor according to claim 3, characterized in that, The multiple first positioning holes and multiple second positioning holes corresponding to each other can be used to insert metal shafts for fixing, and the multiple third positioning holes corresponding to each other can be used for potting and sealing reinforcement.

6. The assembled high-energy-density frameless motor according to claim 1, characterized in that, The frameless motor has an internal rotor structure, with the rotor coaxially disposed inside the stator. The rotor includes a rotor core, and multiple permanent magnets are fixed on the outer ring surface of the rotor core.

7. The assembled high-energy-density frameless motor according to claim 1, characterized in that, The frameless motor has an external rotor structure, with the stator coaxially placed inside the rotor. The rotor includes a rotor core, and multiple permanent magnets are fixed on the inner ring surface of the rotor core.

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