Design method of hollow cup diamond winding

Abstract

The invention discloses a design method of a hollow cup diamond winding, which is characterized in that aiming at the diamond winding of a hollow cup motor, on the basis of ideal power, line load and other parameters of the motor, winding inner and outer diameter parameters are preliminarily calculated, enameled wire specifications are selected, coil layer number, span and other parameters are determined, coil turns, fillet radius and the like are calculated, and then coil resistance and bestrewing rate are obtained. And correcting the parameters according to a calculation result, carrying out comprehensive simulation calculation on the motor, and correcting again until the overall design parameters of the motor are met. Through the implementation of the method, the current situation that domestic hollow cup windings depend on reverse derivation design is broken through, forward design is achieved, various key parameters can be accurately calculated under the limitation of specific space sizes, the design problem is solved, and in addition, the full rate of the windings can be increased and the resistance can be reduced through parameter optimization. The design result can be directly applied to motor simulation and actual production, the research and development period is shortened, and the development of the coreless motor industry is promoted.

Description

Technical Field

[0001] The present invention belongs to the technical field of motor design, and particularly relates to a design method for a hollow cup diamond-shaped winding. Background Art

[0002] In the current era of booming technological development, the fields of medical device machinery and small robots are showing a rapid development trend. Driven by this trend, miniaturized, highly precise and fast-responsive hollow cup motors have been widely used due to their unique advantages, and the market demand for hollow cup motors is increasing day by day.

[0003] The core component of a hollow cup motor is the hollow cup winding, which is significantly different from a general slotted motor. In a general slotted motor, the enameled wire is wound in the iron core slots, while the winding of a hollow cup motor is independently formed and located outside the iron core. This special structure requires comprehensive consideration of many key parameters, such as size, resistance, filling rate, etc., when designing the hollow cup motor winding, and at the same time, the feasibility of the production process must also be taken into account. Summary of the Invention

[0004] To solve the above technical problems, the present invention provides a design method for a hollow cup diamond-shaped winding. The design method for the hollow cup diamond-shaped winding obtains a design of a hollow cup diamond-shaped winding that can meet the motor index requirements by splicing multiple independent coils.

[0005] The present invention is achieved through the following technical solutions.

[0006] A design method for a hollow cup diamond-shaped winding provided by the present invention includes the following steps:

[0007] Step S1, according to the ideal power, linear load, working state, and size space of the motor, preliminarily calculate the inner diameter and outer diameter of the hollow cup winding, select the total number of coils and the axial length, and calculate the center diameter and coil thickness of the hollow cup winding. The specific calculation formulas are as follows: Where D e is the center diameter of the hollow cup winding, δ is the coil thickness, d is the inner diameter of the hollow cup winding, and D is the outer diameter of the hollow cup winding;

[0008] Step S2, select the enameled wire, and calculate the number of layers that can be arranged in the coil space volume through the enameled wire diameter with enamel. The specific calculation formula is as follows: Where, is the enameled wire diameter with enamel, and P le is the allowable number of layers;

[0009] Step S3, calculate the coil span in units of the number of coils from the selected total number of coils and the coil span angle. The specific calculation formula is as follows: Among them, γ1 is the coil span, α is the coil span angle, and S is the total number of coils;

[0010] Step S4: Calculate the 1 / 2 span of the outer side and the 1 / 2 span of the inner side of the coil in units of length based on the center diameter of the air-core cup winding, the total number of coils, and the coil span;

[0011] Step S5: Calculate the theoretical coil bevel angle from the outer side and the axial length of the air-core cup winding, and calculate the coil width of 1 / 4 coil along the arrangement direction from the theoretical coil bevel angle, the center diameter of the air-core cup winding, and the total number of coils;

[0012] Step S6: Select the number of parallel strands and calculate the number of turns that can be arranged within the coil width;

[0013] Step S7: Calculate the outer corner radius of the coil based on the radius of the positioning pin used in practice, the number of turns, and the wire diameter of the enameled wire. The specific calculation formula is: Among them, R o is the outer corner of the coil, and N' s is the calculated single-layer number of turns of the coil;

[0014] Step S8: Calculate the inner axial center distance based on the axial length of the coil and the outer corner radius. The specific calculation formula is: H in = L c - 2(R o - R i )(12), where H in is the inner axial center distance, L c is the axial length, R o is the outer corner of the coil, and R i is the radius of the positioning pin used in practice;

[0015] Step S9: Calculate the inner circumferential center distance of the coil based on the 1 / 2 span of the inner side and the radius of the positioning pin;

[0016] Step S10: Calculate the actual coil bevel angle based on the 1 / 2 span of the inner side and the inner axial center distance;

[0017] Step S11: Calculate the 1 / 4 length of the inner and outer sides of the coil including the winding corner based on the actual coil bevel angle, the 1 / 2 span of the outer side, and the 1 / 2 span of the inner side, and then calculate the 1 / 4 length of the coil center to obtain the total coil length. Multiply the total coil length by the resistivity to obtain the coil resistance;

[0018] Step S12: Calculate the overall space filling rate based on the obtained dimensional parameters, return and correct the corresponding parameters, and obtain the design parameters of the air-core cup winding that can be applied to actual production;

[0019] Step S13: Perform comprehensive motor simulation calculations based on the design parameters of the cup winding, and make corresponding corrections until the overall motor design parameters are met, thus completing the design of the cup-shaped diamond winding.

[0020] The specific calculation formula in the said Step S4 is:

[0021]

[0022] Wherein, is the 1 / 2 span of the outer side, is the 1 / 2 span of the inner side, D e is the center diameter of the cup winding, S is the total number of coils, and γ1 is the coil span.

[0023] The specific calculation formula in the said Step S5 is:

[0024]

[0025] Wherein, θ' edge is the theoretical coil skew angle, is the 1 / 2 span of the outer side, L c is the axial length, W coil is the coil width.

[0026] In the said Step S6, the specific calculation formula is:

[0027]

[0028] Wherein, N s ' is the calculated single-layer number of turns of the coil, is the diameter of the enameled wire with enamel, W coil is the coil width, P l is the value of the number of layers arranged, B prl is the number of parallel windings, and N' is the calculated total number of turns of the coil, that is, the allowable number of turns that can be arranged.

[0029] The specific calculation formula in the said Step S9 is:

[0030]

[0031] Wherein, W in is the center distance of the inner circumference, is the 1 / 2 span of the inner side, R i is the radius of the positioning pin actually used;

[0032] The specific calculation formula in the said Step S10 is:

[0033]

[0034] Among them, θ edge is the actual bevel angle of the coil, H in is the inner axial center distance, is half of the span of the inner side.

[0035] The specific calculation formula in step S11 is as follows:

[0036]

[0037] Among them, is one-fourth of the length of the inner side of the coil, is one-fourth of the length of the outer side of the coil, is one-fourth of the length of the center of the coil, L lap is the total length of the coil, R S is the resistance of the coil, is half of the span of the inner side, θ edge is the actual bevel angle of the coil, R i is the radius of the positioning pin actually used, R o is the outer rounded corner of the coil, N is the number of turns selected for the coil, is the diameter of the copper conductor of the enameled wire, L lap is the total length of the coil, B prl is the number of parallel windings.

[0038] The specific calculation formula for the filling rate in step S12 is as follows:

[0039]

[0040] Among them, η is the filling rate, is the diameter of the enameled wire with enamel coating, N s is the number of turns in a single layer of the coil, S is the total number of coils, θ edge is the actual bevel angle of the coil, d is the inner diameter of the hollow cup winding, is the diameter of the enameled wire with enamel coating.

[0041] The beneficial effects of the present invention are as follows: The design method of the hollow cup diamond-shaped winding of the present invention breaks through the limitation of the traditional reverse derivation design, realizes forward design, accurately calculates the number of turns of the motor winding under specific space size limitations, and then comprehensively obtains key parameters such as resistance and filling rate, successfully overcoming the design problem of the hollow cup diamond-shaped winding. This method can flexibly adjust and optimize the design parameters. For example, in the design example of a 150W hollow cup motor, by thickening the diameter of the enameled wire, the filling rate is increased and the resistance is reduced, improving the space utilization rate. In addition, the designed parameters can be directly applied to motor simulation and actual production, and meet the requirements of the overall design parameters of the motor after comprehensive simulation calculation and correction, which helps to shorten the R & D cycle, reduce costs, and promote the technological progress and development of the hollow cup motor industry. Brief Description of the Drawings

[0042] Figure 1 is a schematic diagram of the method flow of the present invention; Specific embodiments

[0043] The technical solution of the present invention will be further described below, but the scope of protection is not limited thereto.

[0044] The design assumptions of the air-core cup diamond winding are as follows:

[0045] a) The diameter of the enameled wire with enamel is calculated according to the maximum theoretical wire diameter;

[0046] b) The filling rate of the air-core cup winding can reach a range of 100% ± 10%;

[0047] c) The arrangement shape of each turn of enameled wire is a straight line + rounded corner arrangement, and the straight line segment will not bend due to uneven tension or heating temperature stress.

[0048] As Figure 1 shown, a method for designing an air-core cup diamond winding is as follows:

[0049] S1. According to parameters such as the ideal power, linear load, working state, and size space of the motor, preliminarily calculate the inner and outer diameters of the air-core cup winding, and select the total number of coils and the axial length; further calculate the center diameter and coil thickness of the air-core cup winding.

[0050]

[0051] S2. Select the enameled wire specification, and calculate the number of layers that can be arranged in the coil space volume through the enameled wire specification.

[0052]

[0053] S3. From the selected total number of coils and the coil span angle, the coil span in units of the number of coils can be obtained.

[0054]

[0055] S4. From the center diameter of the air-core cup winding, the total number of coils, and the coil span, the 1 / 2 span of the outer side and the 1 / 2 span of the inner side of the coil in units of length can be obtained.

[0056]

[0057] S5. Calculate the theoretical coil angle from the outer side and the axial length of the air-core cup winding; calculate the coil width of 1 / 4 coil along the arrangement direction from the theoretical coil angle, the center diameter of the air-core cup winding, and the total number of coils.

[0058]

[0059] S6. By selecting and winding the number of turns, the number of turns that can be allowed to be arranged within the coil width range is obtained.

[0060]

[0061] S7. According to the radius of the positioning pin, the number of turns, and the diameter of the enameled wire used during production, the radius of the outer rounded corner of the coil is calculated.

[0062]

[0063] S8. According to the axial length of the coil and the radius of the outer rounded corner, the inner axial center distance is calculated.

[0064] H in = L c - 2(R o - R i ) (12)

[0065] S9. According to half of the span of the inner side and the radius of the positioning pin, the inner circumferential center distance of the coil is obtained.

[0066]

[0067] S10. According to half of the span of the inner side and the inner axial center distance, the actual slope angle of the coil is calculated.

[0068]

[0069] S11. According to the actual slope angle of the coil, half of the span of the outer side and half of the span of the inner side, the inner and outer 1 / 4 lengths of the coil including the winding rounded corner are calculated, and then the 1 / 4 length of the coil center is obtained, and the total length is obtained. Multiplying by the resistivity gives the coil resistance.

[0070]

[0071] S12. Calculate the overall space filling rate according to the existing dimensional parameters, return and correct the corresponding parameters to obtain the design parameters of the air-core cup winding that can be applied to actual production.

[0072]

[0073] S13. Perform comprehensive simulation calculations on the motor according to the design parameters of the air-core cup winding and make corresponding corrections until the overall design parameters of the motor are met, and complete the design of the air-core cup diamond winding.

[0074] The definitions of each symbol in the above formula are shown in the following table:

[0075]

[0076] Using the above method, a can-stack motor with a power demand of 150 W was taken as the research object. The winding of this motor has the characteristic of high filling rate. According to the motor size space, the preliminary selected winding size parameters are shown in the following table.

[0077] Definition Dimensions (mm) Inner diameter of winding 11.4 Outer diameter of winding 14.3 Axial length 38

[0078] From equations (1) and (2), the center diameter of the winding is 12.85 mm and the coil thickness is 1.45 mm. The enameled wire gauge of 0.28 mm is selected, and the enamel diameter is 0.331 mm. From equation (3), the number of layers that can be arranged is 2.19 layers.

[0079] The coil span angle is selected as 180°, and the total number of coils is 6. From equation (4), the coil span is 3. From equations (5) and (6), the 1 / 2 span of the outer side and the 1 / 2 span of the inner side are 13.45 mm and 6.73 mm respectively. From equations (7) and (8), the theoretical coil skew angle is 54.7°, and the coil width is 5.49 mm.

[0080] The number of parallel strands is selected as 1. From equations (9) and (10), the number of turns that can be arranged in a single layer is 16.6 turns, and the total number of turns that can be arranged is 33.2 turns. The total number of turns is initially selected as 32 turns.

[0081] From equations (11), (12), and (13), the outer fillet of the coil is 5.8 mm, the inner axial center distance is 27.4 mm, and the inner circumferential center distance is 14.46 mm. From equation (14), the actual coil skew angle is 63.8°. From equations (15) to (19), the coil resistance is 0.718 Ω, and from equation (20), the filling rate is 96%.

[0082] The preliminary design calculation of the diamond-shaped winding is completed. Since the filling rate is 96%, it can be appropriately increased. The enameled wire diameter is thickened by one gauge, and the enameled wire gauge of 0.3 mm is selected, and the enamel diameter is 0.344 mm. Calculations are carried out according to the above steps, and the coil resistance is 0.625 Ω, the filling rate is 100.1%, the overall space utilization rate is higher, and the resistance value is smaller. The comparison of the main parameters is shown in Table 3.

[0083] Table 3 Comparison of Two Schemes of the Can-Stack Winding of 150 W Motor

[0084]

[0085] According to the modified Scheme 2, the overall performance of the motor is calculated, and the rated output power of the motor is 159 W, and the rated efficiency is 80.5%, meeting the design requirements. Thus, the design calculation of the diamond-shaped winding of the can-stack motor is completed.

Claims

1. A design method for hollow cup diamond winding, characterized in that The following steps are involved: Step S1, according to the ideal power, line load, working state, and size space of the motor, preliminarily calculate the inner diameter and outer diameter of the hollow cup winding, select the total number of coils and the axial length, and calculate the center diameter and coil thickness of the hollow cup winding. The specific calculation formula is: (1) (2), where D e is the center diameter of the hollow cup winding, δ is the coil thickness, d is the inner diameter of the hollow cup winding, and D is the outer diameter of the hollow cup winding; Step S2, select the enameled wire, and calculate the number of layers that can be arranged in the coil space volume by the wire diameter of the enameled wire. The specific calculation formula is: (3), where P is the diameter of the enameled wire with paint skin, le To allow for the number of layers to be arranged; Step S3, the coil span in units of the number of coils is calculated based on the total number of selected coils and the coil span angle. The specific calculation formula is: (4), where γ1 is the coil span, α is the coil span angle, and S is the total number of coils; Step S4, calculating the outer side 1 / 2 span and the inner side 1 / 2 span of the coil in length units according to the coreless cup winding center diameter, the total number of coils, and the coil span; Step S5, calculating the theoretical bevel angle of the coil from the outer side and the axial length of the hollow cup winding, and calculating the coil width of 1 / 4 coil along the arrangement direction from the theoretical bevel angle of the coil, the center diameter of the hollow cup winding, and the total number of coils; Step S6, selecting and winding the number of coils, and calculating the number of turns that can be arranged within the width of the coil; Step S7, according to the actual positioning pin radius, number of turns, and enameled wire diameter, the outer corner radius of the coil is calculated. The specific calculation formula is: Among them, R o is the outer corner of the coil, N s 'Calculate the number of single-layer turns for the coil; Step S8, according to the axial length of the coil and the outer fillet radius, the inner axial center distance is calculated. The specific calculation formula is: H in =L c -2(R o -R i )(12), where H in is the inner axial center distance, L c is the axial length, R o is the outer corner of the coil, R i is the actual radius of the positioning pin used; Step S9, calculate the inner circumference center distance of the coil according to the inner side 1 / 2 span and the positioning pin radius, Step S10, calculating the actual bevel angle of the coil according to the inner side 1 / 2 span and the inner axial center distance; Step S11, according to the actual bevel angle of the coil, the 1 / 2 span of the outer side and the 1 / 2 span of the inner side, calculate the inner and outer 1 / 4 lengths of the coil including the winding fillet, and then calculate the 1 / 4 length of the center of the coil to obtain the total length of the coil, and multiply the total length of the coil by the resistivity to obtain the coil resistance, Step S12, calculating the overall space filling rate according to the obtained size parameters, returning and correcting the corresponding parameters, and obtaining the hollow cup winding design parameters that can be applied to actual production; Step S13, performing comprehensive simulation calculation of the motor according to the hollow cup winding design parameters, and making corresponding corrections until the overall design parameters of the motor are met, and completing the design of the hollow cup diamond winding.

2. The design method of the hollow cup diamond winding according to claim 1, characterized in that: The specific calculation formula in step S4 is: in, 1 / 2 of the span of the outer side, The inner side is 1 / 2 of the span, D e is the center diameter of the hollow cup winding, S is the total number of coils, and γ1 is the coil span.

3. The design method of the hollow cup diamond winding according to claim 1, characterized in that: The specific calculation formula in step S5 is: Among them, θ' edge is the theoretical bevel angle of the coil, 1 / 2 of the span of the outer side, L c is the axial length, W coil is the coil width.

4. The design method of the hollow cup diamond winding according to claim 1, characterized in that: In step S6, the specific calculation formula is: Among them, N s 'Calculate the number of turns per layer for the coil, W is the diameter of the enameled wire with paint coating, coil is the coil width, P l is the number of layers to be arranged, B prl is the number of parallel windings, and N' is the total number of turns of the coil, that is, the number of turns that can be arranged.

5. The design method of the hollow cup diamond winding according to claim 1, characterized in that: In step S9, the specific calculation formula is: Among them, W in is the inner circumference center distance, is the inner side 1 / 2 span, R i is the actual radius of the dowel pin used.

6. The design method of the hollow cup diamond winding according to claim 1, characterized in that: In step S10, the specific calculation formula is: Among them, θ edge is the actual bevel angle of the coil, H in is the inner axial center distance, It is 1 / 2 of the inner side span.

7. The design method of the hollow cup diamond winding according to claim 1, characterized in that: The specific calculation formula in step S11 is: in, It is 1 / 4 of the length of the inner side of the coil. It is 1 / 4 of the length of the outer side of the coil. 1 / 4 length of the coil center, L lap is the total length of the coil, R S is the coil resistance, is the inner half span, θ edge is the actual bevel angle of the coil, R i is the actual radius of the positioning pin, R o is the outer corner of the coil, N is the number of turns of the coil, L is the diameter of the enameled copper conductor, lap is the total length of the coil, B prl is the number of winding roots.

8. The design method of the hollow cup diamond winding according to claim 1, characterized in that: The specific calculation formula of the filling rate in step S12 is: Among them, η is the filling rate, The diameter of the enameled wire with paint, N s is the number of turns of a single layer of coil, S is the total number of coils, θ edge is the actual bevel angle of the coil, d is the inner diameter of the hollow cup winding, The wire diameter of the enameled wire with paint coating.

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