Iron core structure

Abstract

The invention discloses an iron core structure which is mainly characterized in that the iron core structure comprises a core body and a core shell, the core body is composed of a magnetic pole, a core body and a core seat, and four screw holes are formed in the bottom of the core seat; the core shell is a rectangular shell with an upper opening, and four penetrating holes which correspond to the four screw holes in the bottom of the core seat and have the same diameter are formed in the bottom of the core shell; two capped screw rods penetrate through two penetrating holes in the middle of the bottom of the core shell to be installed in two screw holes in the middle of the bottom of the core base, and the core body and the core shell are fixed into a whole. After the motor adopts the coil, all magnetic fields of the coil can be effectively concentrated and enhanced, so that the electric energy conversion and utilization of the motor are improved. After the generator adopts the magnetic flux enhancement device, all magnetic fluxes of the coil can be effectively concentrated and enhanced, so that the power generation capacity of the generator is further improved. The device is a detachable independent unit and is convenient to install and maintain.

Description

Technical Field

[0001] The present invention relates to the technical field of motors and generator components, and particularly to an iron core structure. Background Art

[0002] Currently, the iron cores of existing motors are all open designs, resulting in their inability to effectively concentrate and enhance some of the magnetic induction lines outside the wound coils, causing some magnetic fields to dissipate into the surrounding air and resulting in a waste of some electrical energy; the same as the existing motor iron core design, the iron cores of current existing generators are also all open designs, resulting in the loss of some magnetic fluxes outside the coils during the cutting of magnetic force lines by the coils due to their inability to be concentrated, leading to a waste of some magnetic energy. Summary of the Invention

[0003] Aiming at the drawbacks of the existing motor and generator iron cores in the above background art, the purpose of the present invention is to provide an iron core structure that can make up for the drawbacks of the existing motor and generator iron cores.

[0004] The technical solution of the present invention is: an iron core structure, which includes a core body and a core shell. Among them, the core body is composed of magnetic poles, a core body, and a core base. There are 4 screw holes at the bottom of the core base; the core shell is an upper-open rectangular shell, and there are 4 through holes at the bottom of the core shell corresponding to and having the same diameter as the 4 screw holes at the bottom of the core base; the core body and the core shell are fixed into one body by using two cap screw rods to pass through the 2 through holes in the middle of the bottom of the core shell and install them into the 2 screw holes in the middle of the bottom of the core base.

[0005] Further, the magnetic pole of the present invention is a rectangular body with a concave arc surface horizontally throughout the upper end, its thickness is 0.8 - 3.0 millimeters, the center point of its concave arc surface is 0.3 - 1.5 millimeters higher than the upper-open surface of the core shell, and the four sides of its rectangle have the same gap with the inner four walls of the core shell, and the gap is about one-third of the distance from the core body to the inner wall of the core shell;

[0006] Further, the size of the core body of the present invention is calculated according to the fact that it can be fitted into the core shell after the coil winding is completed;

[0007] Further, the size of the core base of the present invention is obtained by fitting it with the inner four walls of the core shell.

[0008] Further, the volume inside the core shell of the present invention is calculated according to the volume of the core body, and its shell thickness is calculated according to the self-weight of the core body and the magnitudes of the suction and repulsion forces generated by the wound coils.

[0009] Further, for the core shell of the present invention, a wire passing hole through which the coil wire can enter and exit is provided at the intersection of the middle of one side surface and its bottom shell;

[0010] Furthermore, the material of the present invention is made of high magnetic permeability materials, such as silicon steel sheets, permalloys, DT4C electrician's pure iron, etc.;

[0011] Furthermore, after the present invention is manufactured according to the dimensions required for the motors and generators to be installed and the above manufacturing method of the present invention, the following steps are carried out for assembly and installation: First, paste high-temperature resistant insulating cloth (film) on the lower plane of the core body and magnetic poles and the upper plane of the core base. Then, wind the coil on the insulating cloth (film) of the core body according to the required number of turns. The coil shall not exceed the length and width of the core base, and the incoming and outgoing wires of the coil shall be left at the corresponding wire passing holes. Second, after winding the high-temperature resistant insulating cloth (film) on the wound coil of the core body, place the core base corresponding to the inner bottom shell of the core shell into the core shell, and then lead out the incoming and outgoing wires of the coil from the wire passing holes. Third, use two cap screw rods to pass through the two through holes in the middle of the bottom of the core shell and install them into the two screw holes in the middle of the bottom of the core base to fix the core body and the core shell as a whole. Fourth, according to the design requirements of the motors and generators to be installed, for several assembled present inventions, use cap screw rods to pass through the yokes of the motors and generators, and then correspondingly pass through the two through holes on the outer side of the bottom of the core shell and install them into the two screw holes on the outer side of the bottom of the core base. In this way, the present invention is installed and ready to be connected to the power supply for use.

[0012] Compared with the iron cores of existing motors and generators, the present invention has the following technical advantages:

[0013] When the motor adopts the present invention, since the core body and the core shell of the present invention can jointly guide magnetic induction lines to form an efficient loop, and since the core shell is made of a high magnetic permeability material, it can not only inhibit the outward diffusion of the internal magnetic field but also block external interfering magnetic fields, thereby increasing the conversion and utilization of electrical energy by the motor. Through example verification, the output torque of the motor adopting the present invention is more than twice that of the motor with the original iron core.

[0014] When the generator adopts the present invention, since the core body and the core shell of the present invention form an efficient loop, when the generator operates and the coil cuts the magnetic induction lines, the magnetic flux generated by the wound coil can be concentrated and enhanced by the efficient loop formed by the present invention, reducing the diffusion and loss of the magnetic flux, thereby further improving the power generation capacity of the generator. Through example verification, the electrical energy produced by the generator adopting the present invention is more than twice that of the generator with the original iron core.

[0015] In addition, the present invention is a detachable independent individual, which provides convenience for the installation and maintenance of the motors and generators adopting the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The present invention will be further described in detail below with reference to the embodiments in the drawings.

[0017] Figure 1 is the schematic diagram of the overall structure of the present invention;

[0018] Figure 2 is the schematic diagram of the core structure of the present invention;

[0019] Figure 3 is the schematic diagram of the core shell of the present invention;

[0020] Figure 4 is the schematic diagram of the bottom of the core shell of the present invention;

[0021] Figure 5 is the schematic diagram of the bottom of the core of the present invention;

[0022] Figure 6 is the schematic diagram of the present invention installed on the yoke of the stator 6 iron core motor with a capped screw rod.

[0023] In the figure: 1 core, 2 core shell, 3 wire passing hole, 4 magnetic pole, 5 core body, 6 core base, 7 yoke, 8 capped screw rod. Detailed implementation manners

[0024] In order to more clearly illustrate the technical solution of the present invention, the following describes the detailed implementation manners of the present invention with reference to the accompanying drawings:

[0025] Refer to Figures 1 to 4 As shown, a core structure includes a core body (1) and a core shell (2). Among them, the core body (1) is composed of a magnetic pole (4), a core body (5) and a core base (6). Four screw holes are provided at the bottom of the core base (6); the core shell (2) is an upper-open rectangular shell, and four through holes corresponding to and having the same diameter as the four screw holes at the bottom of the core base (6) are provided at the bottom of the core shell (2); by using two capped screw rods to pass through two through holes in the middle of the bottom of the core shell (2) and install them into two screw holes in the middle of the bottom of the core base (6), the core body (1) and the core shell (2) are fixed into one body.

[0026] Furthermore, the magnetic pole (3) of the present invention is a rectangular body with a concave arc surface on the upper end transversely throughout, its thickness is 0.8 - 3.0 mm, the center point of its concave arc surface is 0.3 - 1.5 mm higher than the upper open surface of the core shell (2), and the four sides of its rectangle have the same gap with the inner four walls of the core shell (2), and the gap is about one-third of the distance from the core body (5) to the inner wall of the core shell (2);

[0027] Furthermore, the size of the core body (5) of the present invention is calculated according to that it can be fitted into the core shell (2) after the coil winding is completed;

[0028] Further, the size of the core base (6) of the present invention is obtained by fitting it to the inner four walls of the core shell (2).

[0029] Further, the volume inside the core shell (2) of the present invention is calculated based on the volume of the core body (1), and the thickness of its shell is calculated according to the self-weight of the core body (1) and the magnitudes of the suction and repulsion forces generated by the wound coils.

[0030] Further, in the core shell (2) of the present invention, a wire passing hole (3) through which the coil wires can enter and exit is provided at the intersection of the middle of one side surface and the bottom shell.

[0031] Further, the material of the present invention is made of high magnetic permeability materials, such as silicon steel sheets, permalloys, DT4C pure electrical iron, etc.

[0032] Further, after the present invention is manufactured according to the dimensions required for the motors and generators to be installed and the manufacturing method of the present invention described above, the following steps are carried out for assembly and installation: First, heat-resistant insulating cloth (film) is pasted on the lower planes of the core body (5) and the magnetic poles (4) and the upper plane of the core base (6). Then, coils are wound on the insulating cloth (film) of the core body (5) according to the required number of turns. The coils shall not exceed the length and width of the core base (6), and the incoming and outgoing wires of the coils are left at the corresponding wire passing holes (3). Second, after heat-resistant insulating cloth (film) is wound on the coils wound on the core body (5), the core base (6) is placed into the core shell (2) corresponding to the inner bottom shell of the core shell (2), and then the incoming and outgoing wires of the coils are led out from the wire passing holes (3). Third, two cap screw rods are used to pass through the two through holes in the middle of the bottom of the core shell (2) and installed into the two screw holes in the middle of the bottom of the core base (6) to fix the core body (1) and the core shell (2) as a whole. Fourth, according to the design requirements of the motors and generators to be installed, several of the present inventions assembled are installed by using cap screw rods (8) to pass through the yokes (7) of the motors and generators, and then corresponding to pass through the two through holes on the outer side of the bottom of the core shell (2) and installed into the two screw holes on the outer side of the bottom of the core base (6). In this way, the installation of the present invention is completed and waiting for the power supply line to be connected and enabled.

[0033] Compared with the iron cores of existing motors and generators, the present invention has the following technical advantages:

[0034] When the present invention is adopted by a motor, since the core body (1) and the core shell (2) of the present invention can jointly guide magnetic induction lines to form an efficient loop, and since the core shell (2) is made of a high magnetic permeability material, it can not only inhibit the outward diffusion of the internal magnetic field but also block external interfering magnetic fields, thereby increasing the conversion and utilization of electrical energy by the motor. Through example verification, the output torque of the motor adopting the present invention is more than twice that of the motor with the original iron core.

[0035] When the generator adopts the present invention, since the core (1) described in the present invention and the core shell (2) form an efficient loop, when the generator operates and the coil cuts the magnetic lines of force, the magnetic flux generated by the wound coil can be concentrated and enhanced by the efficient loop formed by the present invention, reducing the diffusion loss of the magnetic flux, thereby further enhancing the power generation capacity of the generator. Verified by examples, the electric energy produced by the generator adopting the present invention is more than twice that of the generator with the original iron core.

[0036] In addition, the present invention is a detachable independent individual, which provides convenience for the installation and maintenance of motors and generators adopting the present invention.

[0037] Next, the present invention will be further described with specific embodiments.

[0038] Embodiment 1

[0039] In Embodiment 1 of the present invention, the target motor to be installed is: a DC brushless motor with 12 poles in the stator, 12 volts of voltage, and 500 watts of power (the power is calculated according to the magnetic force generated by the existing iron core and coil of the motor). After actual measurement, the size of the stator iron core of this motor is: 28 mm in length, 10 mm in width, and 18.5 mm in height; the coil is: a copper wire with a diameter of 1 mm wound around the iron core for 64 turns.

[0040] Refer to the above data of the target motor to be installed to implement Embodiment 1 of the present invention:

[0041] First, determine the data of this Embodiment 1: (1) According to the size of the target motor iron core and the wire diameter and number of turns of the wound coil, calculate that the winding thickness of the coil is 4 mm, the height is 16.5 mm, and the gap is 0.3 mm. From this, the size of the core seat is obtained as: 36.6 mm in length, 18.6 mm in width, and 2 mm in thickness; further, the size of the core body is obtained as: 28 mm in length, 10 mm in width, and 16.5 mm in height; (2) According to the size of the core seat and the suction force borne by the magnetic pole, the size of the magnetic pole is obtained as: 34.6 mm in length, 16.6 mm in width, and 1.2 mm in height; (3) According to the size of the core body, the internal volume of the core shell is obtained as: 36.6 mm in length, 18.6 mm in width, and 18.5 mm in height; (4) Considering that the power of the target motor is small and the suction force is also small, the four walls of the core shell adopt a thickness of 2.5 mm and the bottom shell adopts a thickness of 8 mm, and the volume of the core shell is calculated as: 41.6 mm in length, 23.6 mm in width, and 26.5 mm in height;

[0042] Second, permalloy is selected as the material of the core in Embodiment 1. A permalloy blank with a length of 40 mm, a width of 22 mm, and a thickness of 23 mm is precisely milled by a milling machine into a solid core with a length of 36.6 mm, a width of 18.6 mm, and a height of 19.7 mm. Then, a core base is processed with a length of 36.6 mm, a width of 18.6 mm, and a thickness of 2 mm, and 4 screw holes with a diameter of 5 mm are drilled at its bottom; a core body is processed with a length of 28 mm, a width of 10 mm, and a height of 16.5 mm; a magnetic pole is processed with a length of 34.6 mm, a width of 16.6 mm, and a height of 1.2 mm; according to the 12 stators of the target motor, and Embodiment 1 is one of the stators. Therefore, the width of the core shell in Embodiment 1, which is 23.6 mm, is multiplied by 12 and then divided by 3.14, and the diameter of the circle formed by the arcs of the 12 magnetic pole concave arc surfaces in Embodiment 1 is 90.19 mm. The diameter of the rotor of the corresponding target motor should be less than 90.19 mm. Therefore, after leaving a gap, the diameter of the circle formed by the arc of the horizontally through concave arc surface at the top of the magnetic pole in Embodiment 1 is 95 mm. With the center of the circle corresponding to the rotor as the center and a radius of 47.5 mm, after reserving a thickness of 0.7 mm at the top of the magnetic pole, a wire cutting machine is used to horizontally cut the upper end of the magnetic pole into a concave arc surface, and the core in Embodiment 1 is manufactured;

[0043] Third, permalloy is selected as the material of the core shell in Embodiment 1. A permalloy blank with a length of 44 mm, a width of 26 mm, and a thickness of 30 mm is precisely milled by a milling machine into a solid shell with a length of 41.6 mm, a width of 23.6 mm, and a height of 26.5 mm; then, the solid shell with a length of 41.6 mm, a width of 23.6 mm, and a height of 26.5 mm is milled by a milling machine, leaving 2.5 mm thick on each side and 5 mm for the bottom shell, and a hollow body inside the core shell with a length of 36.6 mm, a width of 18.6 mm, and a height of 18.5 mm is milled out. And 4 through holes with a diameter of 5 mm are drilled at the bottom shell corresponding to the 4 screw holes with a diameter of 5 mm at the bottom of the above-mentioned core base; a wire passing hole with a diameter of 3 mm is drilled at the intersection of the middle of the side and the bottom shell, and the core shell in Embodiment 1 is manufactured;

[0044] Fourth, heat-resistant insulating cloth (film) is pasted on the lower planes of the core body and the magnetic pole and the upper plane of the core base. Then, coils are wound on the insulating cloth (film) of the core body according to the required number of turns. The coils shall not exceed the length and width of the core base. The incoming and outgoing wires of the coils are left at the wire passing holes corresponding to the core shell. After heat-resistant insulating cloth (film) is wound on the coils wound on the core body, the core base corresponding to the inner bottom shell of the core shell is placed into the core shell, and then the incoming and outgoing wires of the coils are led out from the wire passing holes;

[0045] Fifth, two screw rods with caps are used to pass through the 2 through holes in the middle of the bottom of the core shell and are installed into the 2 screw holes in the middle of the bottom of the core base, so as to fix the core body and the core shell into one body, and Embodiment 1 of the present invention is completed.

[0046] The following is a test of Embodiment 1 of the present invention:

[0047] Fix Embodiment 1 of the present invention on a steel frame, match a 3-ohm resistor for Embodiment 1 of the present invention, connect a 12-volt DC current. The wattmeter shows that the power of Embodiment 1 of the present invention is 50.4 watts. Use a hook scale with a range of 200 kg to measure the attracted object of Embodiment 1 of the present invention until the final attracted object falls off, and the maximum suction force is obtained as: 78 kg.

[0048] Test the suction force intensity of the iron core monomer of the existing motor: Use the core body of Embodiment 1 of the present invention wrapped with the same coil as above, remove the core shell, and achieve the same iron core structure as the existing motor. Also match a 3-ohm resistor, connect a 12-volt DC current. The wattmeter shows a power of 50.4 watts. Use a hook scale with a range of 200 kg to measure the attracted object of this iron core structure until the final attracted object falls off, and the maximum suction force is obtained as: 33 kg.

[0049] Through the comparison of the above measurement results, it can be obtained that: on the premise of the same voltage, the same power, and the same wound coil, the suction force of Embodiment 1 of the present invention is 2.36 times that of the existing motor iron core, and the expected effect of Embodiment 1 of the present invention is achieved.

[0050] Embodiment 2 (Motor Application Embodiment):

[0051] According to Embodiment 1 of the present invention, make 12; use 24 cap screws to install them on the yoke of a DC brushless motor with a rotor diameter of 94.5 mm, 12 poles of the stator, 12 volts of voltage, and 500 watts of power (the power is matched and calculated according to the magnetic force generated by the existing iron core and coil of the motor). The installation of the motor of Embodiment 1 of the present invention is completed.

[0052] Test the motor installed with Embodiment 1 of the present invention: After starting up with power on, at a rated speed of 3000 revolutions per minute, it is measured that: its output torque is 3.6 N·m.

[0053] Test the use effect of the motor using the existing iron core: Use a DC brushless motor with 12 volts of voltage, 12 poles of the stator, and 500 watts of power (the power is matched and calculated according to the magnetic force generated by the existing iron core and coil of the motor). After starting up with power on, at a rated speed of 3000 revolutions per minute, it is measured that: its output torque is 1.59 N·m.

[0054] Through the comparison of the above measurement results, it can be obtained that: on the premise of the same number of iron cores, the same voltage, the same power, and the same number of revolutions, the output torque of the motor using Embodiment 1 of the present invention is 2.26 times that of the motor using the original iron core.

[0055] Embodiment 3 (Generator Application Embodiment):

[0056] According to Embodiment 1 of the present invention, 12 are manufactured; they are installed on the yoke of an AC generator with a diameter of 94.5 mm for the corresponding rotor, a 12-pole stator, a voltage of 12 V, and a power of 500 W (the power is calculated according to the magnetic force generated by the existing iron core and coil of the generator) using 24 cap screws, and the installation of the generator of Embodiment 1 of the present invention is completed.

[0057] Test the generator installed with Embodiment 1 of the present invention: Use a motor with a power of 500 W (the power is calculated according to the magnetic force generated by the existing iron core and coil of the motor) as the power source. After turning on the power, at 3000 revolutions per minute, measure its electric power output as: 960 W / hour.

[0058] Test the performance of the generator with the original iron core: Use a generator with a 12-pole stator, a voltage of 12 V, and a power of 500 W (the power is calculated according to the magnetic force generated by the existing iron core and coil of the generator), and use a motor with a power of 500 W (the power is calculated according to the magnetic force generated by the existing iron core and coil of the motor) as the power source. After turning on the power, at 3000 revolutions per minute, its electric power output is 450 W / hour.

[0059] From the comparison of the above measurement results, it can be concluded that: on the premise of using motors with the same power, the power generation capacity of the generator of Embodiment 1 of the present invention is 2.13 times that of the generator with the original iron core.

[0060] As described above, this is a preferred embodiment of the present invention. Those skilled in the art should cover any equivalent replacement or modification within the technical scope disclosed by the present invention and based on the technical solution and inventive concept of the present invention within the protection scope of the present invention.

Claims

1. A core structure, comprising a core body (1) and a core shell (2), characterized in that: The described core body (1) is composed of a magnetic pole (4), a core body (5), and a core base (6). Four screw holes are provided at the bottom of the core base (6). The core shell (2) is an upper-open rectangular shell, and four through holes with the same diameter corresponding to the four screw holes at the bottom of the core base (6) are provided at the bottom of the core shell (2). The core body (1) and the core shell (2) are fixed together by installing two capped screw rods through the two through holes in the middle of the bottom of the core shell (2) and into the two screw holes in the middle of the bottom of the core base (6).

2. The iron core structure according to claim 1, characterized in that: The magnetic pole (3) described in the present invention is a rectangular body with a concave arc surface throughout the upper end transversely. Its thickness is 0.8 - 3.0 mm. The center point of the concave arc surface is 0.3 - 1.5 mm higher than the upper-open surface of the core shell (2). The four sides of the rectangle have the same gap with the inner four walls of the core shell (2), and the gap is about one-third of the distance from the core body (5) to the inner wall of the core shell (2).

3. A core structure according to claim 1, characterized in that: The size of the core body (5) described in the present invention is calculated based on its ability to fit into the core shell (2) after the coil winding is completed.

4. A core structure according to claim 1, characterized in that: The size of the core base (6) described in the present invention is obtained by fitting it with the inner four walls of the core shell (2).

5. A core structure according to claim 1, characterized in that: The volume inside the core shell (2) described in the present invention is calculated based on the volume of the core body (1), and its shell thickness is calculated based on the self-weight of the core body (1) and the magnitudes of the suction and repulsion forces generated by the wound coil.

6. A core structure according to claim 1, characterized in that: For the core shell (2) described in the present invention, a wire passing hole (3) through which the coil wire can enter and exit is provided at the intersection of the middle of one side surface and its bottom shell.

7. A core structure according to claim 1, characterized in that: The present invention is installed on the yoke (7) of the motor or generator to be installed by using a capped screw rod (8).

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