Synchronous motor winding method

Abstract

The invention provides a synchronous motor winding method, and relates to the technical field of motor winding. According to the winding method of the synchronous motor, a first winding unit and a second winding unit are included, the first winding unit comprises three phases of phase lines A1, B1 and C1, the second winding unit comprises three phases of phase lines A2, B2 and C2, and the first winding unit and the second winding unit are wound on the same stator teeth in parallel. Each phase of winding coil of the first winding unit and the second winding unit is wound on two stator teeth to form a group, the first winding unit and the second winding unit adopt a star connection method, and the ending parts of the two winding units are gathered together. According to the invention, the double winding units are wound in parallel, so that the slot fullness rate can be effectively improved, the copper loss is reduced, the power density is improved, the magnetic flux distribution is optimized by alternating the winding directions, the eddy current loss can be effectively reduced, and the efficiency is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of motor winding, and specifically to a winding method for synchronous motors. Background Art

[0002] As a key device in fields such as industrial drive and new energy power generation, the performance of synchronous motors directly depends on the winding quality of stator or rotor coils. The winding process of coils directly affects the electromagnetic characteristics, efficiency, and reliability of motors. Therefore, optimizing the winding method is the core link to improve the overall performance of motors.

[0003] The stator windings of traditional synchronous motors mostly adopt a single winding unit structure, which has problems such as low power density, large electromagnetic harmonics, and uneven temperature rise. Although there are dual-winding designs in the prior art, most of them use stratified or slot-by-slot winding, resulting in complex structures and high manufacturing costs. In addition, the winding connection method is single, making it difficult to balance efficiency and stability.

[0004] Therefore, there is an urgent need for a stator winding scheme with a simple structure that can effectively reduce harmonics and increase power density. Summary of the Invention

[0005] (1) Technical Problems to be Solved

[0006] In view of the deficiencies of the prior art, the present invention provides a winding method for synchronous motors, which solves the problems of large electromagnetic harmonics and uneven temperature rise.

[0007] (2) Technical Solutions

[0008] To achieve the above objectives, the present invention is realized through the following technical solutions:

[0009] A winding method for synchronous motors, including a first winding unit and a second winding unit. The first winding unit includes three-phase phase lines A1, B1, and C1, and the second winding unit includes three-phase phase lines A2, B2, and C2. The first winding unit and the second winding unit are wound in parallel on the same stator teeth. Each phase winding coil of the first winding unit and the second winding unit is wound on 2 stator teeth as a group. Both the first winding unit and the second winding unit adopt a star connection method, and the ends of the two winding units are gathered together;

[0010] The winding method includes the following steps:

[0011] S1. Stack silicon steel sheets into a stator core, and perform slotting. Divide the stator teeth into groups with two adjacent teeth as a group;

[0012] S2. Use a numerical control winding machine to set the wire diameter, number of turns, and winding direction;

[0013] S3. Perform winding. Wind A1 and A2 in parallel around the first tooth group (tooth 1 - 2), and then wind the other end around the fourth tooth group (tooth 7 - 8);

[0014] S4. Wind B1 and B2 in parallel around the second tooth group (tooth 3 - 4), and then wind the other end around the fifth tooth group (tooth 9 - 10);

[0015] S5. Wind C1 and C2 in parallel around the third tooth group (tooth 5 - 6), and then wind the other end around the sixth tooth group (tooth 11 - 12);

[0016] S6. After the winding is completed, perform high - temperature curing treatment on the whole to ensure that the insulating material is tightly combined with the wire;

[0017] S7. Independently lead out the starting ends (A1, B1, C1) of the first winding unit and the starting ends (A2, B2, C2) of the second winding unit respectively, and mark them as three - phase input terminals. Connect the ends of the first winding unit and the second winding unit to the same neutral point through a copper bar or welding process to form a star connection;

[0018] S8. Use an LCR meter to measure the resistance and inductance values of each phase winding to ensure that the consistency deviation ≤ 5%. Apply a test voltage 1.5 times the rated voltage to detect whether the insulation performance meets the standard. Connect to a driver for load testing to verify the efficiency, temperature rise, and harmonic performance.

[0019] Further, in step S2, the wire diameter is 0.8 mm and the number of turns is 10. When A1 and A2 pass through tooth 1 in the first tooth group and tooth 7 in the fourth tooth group in step S3, it is counter - clockwise, and when passing through tooth 2 in the first tooth group and tooth 8 in the fourth tooth group, it is clockwise. When B1 and B2 pass through tooth 3 in the second tooth group and tooth 9 in the fifth tooth group in step S4, it is counter - clockwise, and when passing through tooth 4 in the second tooth group and tooth 10 in the fifth tooth group, it is clockwise. When C1 and C2 pass through tooth 5 in the third tooth group and tooth 12 in the sixth tooth group in step S5, it is counter - clockwise, and when passing through tooth 6 in the third tooth group and tooth 11 in the sixth tooth group, it is clockwise.

[0020] Further, after each phase is wound in steps S3, S4, and S5, insert a high - temperature - resistant polyimide film between the wire layers to ensure insulation between windings.

[0021] (III) Beneficial effects

[0022] The present invention provides a synchronous motor winding method, which has the following beneficial effects:

[0023] 1. The present invention provides a winding method for a synchronous motor. By parallel winding of double winding units, the slot fill factor can be effectively increased, copper loss is reduced, and power density is improved. Then, by alternating the winding direction to optimize the magnetic flux distribution, eddy current loss can be effectively reduced and efficiency can be improved.

[0024] 2. The present invention provides a winding method for a synchronous motor. By using a high-temperature resistant polyimide film for interlayer insulation and a high-temperature curing process, a composite insulation system with a temperature resistance of 220 °C is formed, which reduces the winding temperature rise by 10 - 15 K, effectively improves the adhesion of the insulation layer, completely solves the risk of high-temperature delamination, and cooperates with the numerical control winding process and LCR on-line detection to effectively control the three-phase unbalance degree and effectively reduce the vibration and noise, ensuring long-term stable operation under high-load scenarios. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 is a schematic structural diagram of the winding method of the present invention;

[0026] Figure 2 is a load characteristic curve of a synchronous motor using the winding method of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0027] The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0028] Embodiment 1:

[0029] A winding method for a synchronous motor includes a first winding unit and a second winding unit. The first winding unit includes three-phase phase lines A1, B1, and C1, and the second winding unit includes three-phase phase lines A2, B2, and C2. The first winding unit and the second winding unit are wound in parallel on the same stator teeth. Each phase winding coil of the first winding unit and the second winding unit is wound on 2 stator teeth as a group. The first winding unit and the second winding unit both adopt a star connection method, and the end parts of the two winding units are gathered together;

[0030] The winding method includes the following steps:

[0031] S1. Stack silicon steel sheets into a stator core, and perform slotting. Divide the stator teeth into groups with two adjacent teeth as a group;

[0032] S2. Use a numerical control winding machine to set the wire diameter, number of turns, and winding direction;

[0033] S3. Perform winding. Wind A1 and A2 in parallel around the first tooth group (tooth 1 - 2), and then wind the other end around the fourth tooth group (tooth 7 - 8);

[0034] S4. Wind B1 and B2 in parallel around the second tooth group (tooth 3 - 4), and then wind the other end around the fifth tooth group (tooth 9 - 10);

[0035] S5. Wind C1 and C2 in parallel around the third tooth group (tooth 5 - 6), and then wind the other end around the sixth tooth group (tooth 11 - 12);

[0036] S6. After the winding is completed, perform high - temperature curing treatment on the whole to ensure that the insulating material is tightly combined with the wire;

[0037] S7. Independently lead out the starting ends (A1, B1, C1) of the first winding unit and the starting ends (A2, B2, C2) of the second winding unit respectively, mark them as three - phase input terminals, and connect the ends of the first winding unit and the second winding unit to the same neutral point through a copper bar or welding process to form a star connection;

[0038] S8. Use an LCR meter to measure the resistance and inductance values of each phase winding to ensure that the consistency deviation ≤ 5%. Apply a test voltage 1.5 times the rated voltage to detect whether the insulation performance meets the standard, and connect to a driver for load testing to verify the efficiency, temperature rise, and harmonic performance.

[0039] In step S2, the wire diameter is 0.8 mm and the number of turns is 10. When A1 and A2 pass through tooth 1 in the first tooth group and tooth 7 in the fourth tooth group in step S3, it is counter - clockwise, and when passing through tooth 2 in the first tooth group and tooth 8 in the fourth tooth group, it is clockwise. When B1 and B2 pass through tooth 3 in the second tooth group and tooth 9 in the fifth tooth group in step S4, it is counter - clockwise, and when passing through tooth 4 in the second tooth group and tooth 10 in the fifth tooth group, it is clockwise. When C1 and C2 pass through tooth 5 in the third tooth group and tooth 12 in the sixth tooth group in step S5, it is counter - clockwise, and when passing through tooth 6 in the third tooth group and tooth 11 in the sixth tooth group, it is clockwise.

[0040] After each phase is wound in step S3, step S4, and step S5, insert a high - temperature - resistant polyimide film between the wire layers to ensure insulation between windings.

[0041] Embodiment 2:

[0042] The winding method of a synchronous motor has the following steps:

[0043] S1. Stack silicon steel sheets to form a stator core. After slotting, divide two adjacent teeth into a group, with a total of 6 groups: the first tooth group (tooth 1 - 2), the second tooth group (tooth 3 - 4), the third tooth group (tooth 5 - 6), the fourth tooth group (tooth 7 - 8), the fifth tooth group (tooth 9 - 10), and the sixth tooth group (tooth 11 - 12).

[0044] S2. Wire diameter: 0.8 mm, number of turns: 10 turns / coil; winding direction: the winding directions of adjacent teeth within each group of teeth are opposite (alternating counterclockwise → clockwise).

[0045] S3. Wind phase A (A1, A2), winding path: the first tooth group (tooth 1 - 2) → the fourth tooth group (tooth 7 - 8), direction: wind teeth 1 and 7 counterclockwise, wind teeth 2 and 8 clockwise. After winding, insert a high - temperature resistant polyimide film. Wind phase B (B1, B2), winding path: the second tooth group (tooth 3 - 4) → the fifth tooth group (tooth 9 - 10), direction: wind teeth 3 and 9 counterclockwise, wind teeth 4 and 10 clockwise. Insulation treatment: the same as phase A. Wind phase C (C1, C2), winding path: the third tooth group (tooth 5 - 6) → the sixth tooth group (tooth 11 - 12), direction: wind teeth 5 and 12 counterclockwise, wind teeth 6 and 11 clockwise. Insulation treatment: the same as phase A.

[0046] S4. After the overall winding is completed, perform high - temperature curing to ensure that the insulating material is tightly combined with the wire. Connect in star connection, and independently lead out the starting ends: the starting ends of the first winding (A1, B1, C1) and the second winding (A2, B2, C2) are respectively marked as three - phase input terminals, and the ends are commonly connected to the neutral point: the ends of the two windings are connected to the same neutral point through a copper bar or welding.

[0047] S5. Use an LCR meter to measure the resistance and inductance of each phase, with the consistency deviation ≤ 5%. Apply 1.5 times the rated voltage to detect the insulation performance. Connect to a driver for load testing to verify the efficiency, temperature rise, and harmonic performance.

[0048] Although the embodiments of the present invention have been shown and described, for those of ordinary skill in the art, it can be understood that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for winding a synchronous motor, characterized in that, It includes a first winding unit and a second winding unit. The first winding unit includes three-phase phase lines A1, B1, and C1. The second winding unit includes three-phase phase lines A2, B2, and C2. The first winding unit and the second winding unit are wound in parallel on the same stator teeth. Each phase winding coil of the first winding unit and the second winding unit is wound on 2 stator teeth as a group. Both the first winding unit and the second winding unit adopt a star connection method, and the end parts of the two winding units are gathered together; The winding method includes the following steps: S1. Stack silicon steel sheets into a stator core, perform slotting, and divide the stator teeth into groups with two adjacent teeth as a group; S2. Use a numerical control winding machine to set the wire diameter, number of turns, and winding direction; S3. Perform winding. Wind A1 and A2 in parallel on the first tooth group (tooth 1-2), and then wind the other end on the fourth tooth group (tooth 7-8); S4. Wind B1 and B2 in parallel on the second tooth group (tooth 3-4), and then wind the other end on the fifth tooth group (tooth 9-10); S5. Wind C1 and C2 in parallel on the third tooth group (tooth 5-6), and then wind the other end on the sixth tooth group (tooth 11-12); S6. After winding is completed, perform high-temperature curing treatment on the whole to ensure that the insulating material is tightly combined with the wire; S7. Independently lead out the starting ends (A1, B1, C1) of the first winding unit and the starting ends (A2, B2, C2) of the second winding unit, and mark them as three-phase input terminals. Connect the ends of the first winding unit and the second winding unit to the same neutral point through a copper bar or welding process to form a star connection method; S8. Use an LCR meter to measure the resistance and inductance values of each phase winding to ensure that the consistency deviation ≤ 5%. Apply a test voltage 1.5 times the rated voltage to detect whether the insulation performance meets the standard. Connect to a driver for load testing to verify the efficiency, temperature rise, and harmonic performance.

2. The winding method of the synchronous motor according to claim 1, characterized in that: In step S2, the wire diameter is 0.8 mm and the number of turns is 10. In step S3, when A1 and A2 pass through tooth 1 in the first tooth group and tooth 7 in the fourth tooth group, it is counterclockwise, and when passing through tooth 2 in the first tooth group and tooth 8 in the fourth tooth group, it is clockwise. In step S4, when B1 and B2 pass through tooth 3 in the second tooth group and tooth 9 in the fifth tooth group, it is counterclockwise, and when B1 and B2 pass through tooth 4 in the second tooth group and tooth 10 in the fifth tooth group, it is clockwise. In step S5, when C1 and C2 pass through tooth 5 in the third tooth group and tooth 12 in the sixth tooth group, it is counterclockwise, and when C1 and C2 pass through tooth 6 in the third tooth group and tooth 11 in the sixth tooth group, it is clockwise.

3. The winding method of the synchronous motor according to claim 1, characterized in that: After each phase is wound in step S3, step S4, and step S5, insert a high-temperature resistant polyimide film between the wire layers to ensure insulation between windings.

Images