Winding overlapping calculation method of stator winding circuit board

Abstract

The invention discloses a winding overlapping calculation method of a stator winding circuit board, which comprises the following steps of: decomposing a circuit board winding into a plurality of geometric units, defining a wire path, a wire width and an interlayer distance of each layer, then introducing a three-dimensional coordinate system, and marking a spatial position and a current direction of each unit; solving a Maxwell equation set by adopting a finite element method, and obtaining magnetic field intensity distribution of the overlapping region; calculating eddy-current loss and copper loss according to magnetic field distribution, and predicting a temperature field by combining a heat conduction equation; iteratively adjusting the width and the angle of the overlapping region by taking loss minimization and heat dissipation uniformization as targets; an overlapping coefficient # imgabs0 # is defined, wherein Aoverlapping is the overlapping area, and Atotal is the total lead area; and determining an optimal overlapping parameter according to a constraint condition that K belongs to [0.2, 0.5] and a temperature rise threshold value delta T is less than or equal to 15 DEG C. Through quantitative analysis of electromagnetic field and thermal field distribution, motor efficiency and reliability are improved, and the method is suitable for winding optimization design of precision motors such as permanent magnet motors and stepping motors.

Description

Technical Field

[0001] The present invention relates to the field of motor design and manufacturing, and particularly to a method for calculating winding overlap of a stator winding circuit board. Background Art

[0002] Traditional stator windings are wound manually or mechanically, which have problems such as low efficiency, poor accuracy, and easy generation of electromagnetic interference. Although the existing circuit board winding technology can improve consistency, there is a lack of systematic methods for optimizing the winding overlap area, resulting in the following defects:

[0003] 1. Poor electromagnetic compatibility: The unreasonable design of the winding overlap area easily causes local magnetic field distortion and increases eddy current loss.

[0004] 2. Uneven heat dissipation: The heat distribution in the overlap area is not quantitatively analyzed, affecting the service life of the motor.

[0005] 3. Dependence on empirical parameters: Existing methods are mostly based on fixed empirical formulas and are difficult to adapt to variable motor topologies. Summary of the Invention

[0006] In view of the above problems, the present invention provides a method for calculating winding overlap of a stator winding circuit board, which improves the efficiency and reliability of the motor by quantitatively analyzing the electromagnetic field and thermal field distributions, and is applicable to the winding optimization design of precision motors such as permanent magnet motors and stepper motors.

[0007] The technical solution adopted by the present invention is as follows:

[0008] A method for calculating winding overlap of a stator winding circuit board, comprising the following steps:

[0009] Establish a hierarchical model:

[0010] Decompose the circuit board winding into multiple geometric units, and define the wire path, wire width, and interlayer spacing of each layer;

[0011] Introduce a three-dimensional coordinate system, and mark the spatial position and current direction of each unit;

[0012] Electromagnetic-thermal coupling analysis:

[0013] Magnetic field calculation: Solve Maxwell's equations using the finite element method (FEM) to obtain the magnetic field intensity distribution in the overlap area;

[0014] Loss modeling: Calculate eddy current loss and copper loss according to the magnetic field distribution, and predict the temperature field in combination with the heat conduction equation;

[0015] Dynamic optimization: Iteratively adjust the width and angle of the overlap area with the goals of minimizing loss and uniform heat dissipation;

[0016] Quantitative evaluation of the overlap area:

[0017] Define the overlap coefficient where A overlap is the overlapping area, and A total is the total conductor area;

[0018] Determine the optimal overlap parameters through the constraint conditions K∈[0.2, 0.5] and the temperature rise threshold ΔT≤15°C.

[0019] In a further technical solution, the finite element method is used to solve the eddy current loss in the magnetic field analysis.

[0020] In a further technical solution, the dynamic optimization uses the genetic algorithm to iteratively adjust the overlap angle and width.

[0021] In a further technical solution, the edge effect correction factor β = 1 - e -d / δ is introduced, where d is the edge distance and δ is the skin depth.

[0022] In a further technical solution, in the thermal field analysis, the calculation results of the eddy current loss and the copper loss are input into the heat conduction equation to predict the temperature field distribution in the overlapping area.

[0023] In a further technical solution, the adjustment range of the overlap angle is 10° - 60°, and the adjustment accuracy of the overlap width is ±0.05 mm.

[0024] The beneficial effects of the present invention are as follows:

[0025] 1. For the first time, the coupled analysis of the electromagnetic field and the thermal field is applied to the winding overlap design;

[0026] 2. The genetic algorithm (GA) is used to automatically optimize the parameters to adapt to different motor topologies;

[0027] 3. The correction factor β is introduced to eliminate the influence of magnetic field distortion at the edge of the circuit board;

[0028] 4. The present invention is applicable to permanent magnet synchronous motors with 12 slots or more, and the input parameters include wire width 0.3 - 0.8 mm, layer spacing 0.1 - 0.3 mm, and current density 4 - 8 A / mm 2 ;

[0029] 5. After optimization, the winding efficiency is increased by ≥5%, and the electromagnetic interference is reduced by ≥10 dB. Specific embodiments

[0030] The embodiments of the present invention will be described in detail below.

[0031] Embodiment:

[0032] A winding overlap calculation method for a stator winding circuit board, comprising the following steps:

[0033] Establish a hierarchical model:

[0034] Decompose the circuit board winding into multiple geometric units, and define the wire path, wire width, and interlayer spacing of each layer;

[0035] Introduce a three-dimensional coordinate system, and mark the spatial position and current direction of each unit;

[0036] Electromagnetic-thermal coupling analysis:

[0037] Magnetic field calculation: Use the finite element method (FEM) to solve Maxwell's equations to obtain the magnetic field strength distribution in the overlapping region;

[0038] Loss modeling: Calculate the eddy current loss and copper loss according to the magnetic field distribution, and predict the temperature field in combination with the heat conduction equation;

[0039] Dynamic optimization: With the goal of minimizing loss and uniform heat dissipation, iteratively adjust the width and angle of the overlapping region;

[0040] Quantitative evaluation of the overlapping region:

[0041] Define the overlap coefficient where A overlap is the overlapping area, and A total is the total wire area;

[0042] Determine the optimal overlap parameters through the constraint conditions K∈[0.2,0.5] and the temperature rise threshold ΔT≤15°C.

[0043] In another embodiment, the finite element method is used to solve the eddy current loss in the magnetic field analysis.

[0044] In another embodiment, the dynamic optimization uses a genetic algorithm to iteratively adjust the overlap angle and width.

[0045] In another embodiment, an edge effect correction factor β = 1 - e -d / δ is introduced, where d is the edge distance and δ is the skin depth.

[0046] In another embodiment, in the thermal field analysis, the calculation results of the eddy current loss and copper loss are input into the heat conduction equation ▽·(k▽T)+Q = 0 to predict the temperature field distribution in the overlapping region.

[0047] In another embodiment, the adjustment range of the overlap angle is 10° - 60°, and the adjustment accuracy of the overlap width is ±0.05 mm.

[0048] The above-described embodiments merely represent specific implementation manners of the present invention. The description is relatively specific and detailed, but it should not be construed as a limitation on the scope of the patent for the present invention. It should be noted that for those of ordinary skill in the art, without departing from the concept of the present invention, several modifications and improvements can still be made, and these all fall within the protection scope of the present invention.

Claims

1. A method for calculating the winding overlap of a stator winding circuit board, characterized in that, It includes the following steps: Establish a hierarchical model: Decompose the circuit board winding into multiple geometric units, and define the wire path, wire width, and interlayer spacing for each layer; Introduce a three-dimensional coordinate system to mark the spatial positions and current directions of each unit; Electromagnetic-thermal coupling analysis: Magnetic field calculation: Solve the Maxwell equations using the finite element method to obtain the magnetic field strength distribution in the overlapping region; Loss modeling: Calculate the eddy current loss and copper loss based on the magnetic field distribution, and predict the temperature field in combination with the heat conduction equation; Dynamic optimization: Iteratively adjust the width and angle of the overlapping region with the goals of minimizing losses and uniform heat dissipation; Quantitative evaluation of the overlapping region: Define the overlap coefficient where A overlap is the overlapping area, and A total is the total conductor area; Determine the optimal overlapping parameters through the constraint conditions K ∈ [0.2, 0.5] and the temperature rise threshold ΔT ≤ 15°C.

2. The winding overlap calculation method of the stator winding circuit board according to claim 1, characterized in that The finite element method is used to solve the eddy current loss in the magnetic field analysis.

3. The winding overlap calculation method of the stator winding circuit board according to claim 1, characterized in that The dynamic optimization uses a genetic algorithm to iteratively adjust the overlapping angle and width.

4. The winding overlap calculation method of the stator winding circuit board according to claim 1, characterized in that, Introduce the edge effect correction factor β = 1 - e -d / δ , where d is the edge distance and δ is the skin depth.

5. The winding overlap calculation method of the stator winding circuit board according to claim 1, characterized in that In the thermal field analysis, the calculation results of the eddy current loss and copper loss are input into the heat conduction equation ▽·(k▽T)+Q = 0 to predict the temperature field distribution in the overlapping region.

6. The winding overlap calculation method of the stator winding circuit board according to claim 1, characterized in that The adjustment range of the overlapping angle is 10° - 60°, and the adjustment accuracy of the overlapping width is ±0.05 mm.

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