A method of manufacturing a motor winding

Abstract

A motor winding preparation method comprises the following steps: S1, for the prefabricated copper plate blank workpiece, the conductor wire segment cutting and the insulating glue caulking fixing are completed, the relative position of the divided conductor main body and the visual positioning hole is kept consistent; S2, the conductor lead and the short circuit wire cutting, S3, the conductor lead and the short circuit wire insulating glue caulking fixing; S4, the UV light curing glue on the workpiece is secondarily heat cured, and the final caulking fixing effect is obtained; S5, the conductor copper plate residual glue is removed; S6, the conductor copper plate inner and outer electrical connection point cutting, the conductor inner and outer electrical connection points are cut and divided by laser to form independent electrical connection points; winding hot pressing and electrical connection point connection, the conductor copper plate and the PP sheet are stacked in multiple layers and aligned with the inner and outer electrical connection points connected with each other, the stacked conductor copper plate and the PP sheet are fixed, and the conductor copper plate and the PP sheet are bonded and pressed in the vacuum hot press and the upper and lower electrical connection points in the corresponding position are connected in electrical connection.

Description

Technical Field

[0001] This invention belongs to the field of motor manufacturing technology, specifically relating to a method for preparing motor windings. Background Technology

[0002] In current motor manufacturing processes, motor windings are typically produced using enameled wire winding, braiding, or PCB printing. Enameled wire windings result in waste in terms of motor structural space utilization and materials, namely low winding slot coverage, excessively long end conductors, and significant carbon emissions during the production of enameled wire, the raw material for windings. Processes such as annealing, painting, baking, and cooling, as well as hazardous waste treatment, require more energy and auxiliary materials. PCB printed windings require processes such as lamination, exposure, development, etching, and stripping to produce winding conductors, involving chemicals such as acids, alkalis, and inks, which also require additional energy consumption for hazardous waste treatment.

[0003] The existing technologies mentioned above lack effective technical measures to reduce raw materials and carbon emissions in the overall production of traditional motor windings. Summary of the Invention

[0004] In view of this, and in light of the shortcomings of the existing technology, the purpose of this application is to provide a method for preparing motor windings, which overcomes the technical problems of waste in space utilization and materials in traditional motor structures and large carbon emissions during the production process. The motor windings prepared by the present invention using laser cutting and hot pressing can obtain motor windings with optimized size and excellent electromechanical performance. They are flat wire windings with advantages such as short winding ends, high power density and strong heat dissipation.

[0005] To achieve the above and other related objectives, this application provides a method for manufacturing motor windings. The method utilizes pure copper plates and employs laser cutting and multi-layer stacking pressing as the primary processes for manufacturing motor windings. The method includes the following steps:

[0006] S1. For the prefabricated copper plate blank workpiece, complete the conductor segment cutting and insulating glue filling and fixing. The conductor body on the copper plate is divided by laser cutting, and the cut is filled with insulating glue and the conductor body on both sides of the cut is glued and bonded with glue, so that the relative position of the divided conductor body is consistent with the visual positioning hole.

[0007] S2, conductor lead and jumper wire cutting, cut the winding leads or jumper wires according to the needs of the circuit diagram;

[0008] S3, Insulation glue is used to fill and fix the conductor leads and short wires. The cut is filled with insulation glue and the glue is cured to bond the conductor leads or short wires on both sides of the cut, so that the relative position of the cut conductor leads or short wires is consistent with the visual positioning hole.

[0009] S4, cure the insulating adhesive on the workpiece to obtain the final filling and fixing effect; such as resin adhesive or UV curing adhesive can meet the needs of this application;

[0010] S5, Remove residual adhesive from conductor copper plate: Grind and remove the residual adhesive left on the surface of the cut copper plate to ensure that there are no conductive impurities embedded between the conductors cut on the copper plate.

[0011] S6, Cutting the inner and outer pads of the conductor copper plate, laser cutting and dividing the inner and outer pads of the conductor, i.e. the connection points, to form independent electrical connection points;

[0012] S7, winding hot pressing and electrical connection point connection, multi-layer stacking of conductor copper plate and PP sheet and alignment of internal and external electrical connection points, fixing the stacked conductor copper plate and PP sheet, and placing them in a vacuum hot press for bonding and pressing of conductor copper plate and PP sheet and electrical connection of corresponding upper and lower electrical connection points.

[0013] The technical solution provided in this application also includes the following technical features:

[0014] Preferably, in one embodiment of this application, the pre-fabricated copper plate blank workpiece in S1 is obtained through the following steps: blanking the copper plate to obtain the copper plate workpiece, shaping the copper plate workpiece, cutting visual positioning holes and process holes on the copper plate, and deburring the copper plate workpiece;

[0015] Copper plate shaping involves shaping uneven copper plate blanks to achieve the required flatness.

[0016] Visual positioning holes and process holes are cut using laser cutting methods. Visual positioning holes are used for visual positioning, identification, and differentiation.

[0017] Deburring of copper plate workpieces and cleaning of residual molten slag adhering to the cut upper and lower surfaces;

[0018] The insulating adhesive is a transparent, colorless UV-curable adhesive or resin adhesive;

[0019] Electrical connections are made using physical welding methods such as reflow soldering and laser welding.

[0020] Preferably, in one embodiment of this application, the flatness tolerance of the copper plate after shaping in S1 does not exceed 0.1 mm.

[0021] Preferably, in one embodiment of this application, the secondary thermosetting parameters in S4 are: the insulating adhesive on the workpiece is cured by heating at 110°C within 6 minutes.

[0022] Preferably, in one embodiment of this application, step S7 is included:

[0023] Deburr, remove slag and conductive impurities from electrical connection points, seams, and upper and lower surfaces;

[0024] Pre-treatment of conductor electrical connection points involves grinding and cleaning the conductor pad connection surface to remove oxide scale, oil, and other substances that are detrimental to welding.

[0025] Apply solder paste by screen printing it onto the electrical connection surfaces to ensure the solder paste is fully applied.

[0026] Pretreatment of solder paste for electrical connection points involves low-temperature baking and dehydration of the solder paste on the conductor copper plate.

[0027] Preferably, in one embodiment of this application, in S7, solder paste is applied by scraping, and the thickness of the stencil printed by screen printing is 0.2 mm.

[0028] Preferably, in one embodiment of this application, step S8 is included:

[0029] The winding hot pressing and electrical connection of the electrical connection points are carried out by stacking multiple layers of conductor copper plates and PP sheets that have been pretreated with solder paste and aligning the internal and external electrical connection points to be connected. The stacked conductor copper plates and PP sheets are fixed and placed in a vacuum hot press for bonding and pressing of conductor copper plates and PP sheets and reflow soldering of solder paste to connect the upper and lower electrical connection points at the corresponding positions.

[0030] Preferably, in one embodiment of this application, step S9 is included:

[0031] Visual inspection and quality control: Visual inspection is performed on the pressed and bonded semi-finished windings to check for solder overflow and adhesion or conductive impurities in the gaps between the pads. Minor defects are addressed with laser cleaning and other quality control measures.

[0032] Preferably, in one embodiment of this application, step S10 is included:

[0033] Sealing the electrical connection points with adhesive and filling the gaps between the inner and outer electrical connection points with insulating adhesive to ensure insulation between the electrical connection points, the inner and outer rings, and the solder pad connection points.

[0034] The inner and outer process edges are milled and removed. A CNC milling machine is used to mill and remove the inner and outer process edges, so that there are no sticky copper chips between the inner and outer pads and the gaps are clear. The CNC milling machine can also be a CNC multi-axis machine tool, as long as it includes milling machining process.

[0035] Preferably, in one embodiment of this application, step S11 is included:

[0036] Pre-treatment of winding leads: Welding and insulation treatment of phase winding leads of the pressed motor windings;

[0037] Electrical performance testing of windings, including phase winding resistance testing, phase-to-phase insulation testing, and current carrying capacity testing;

[0038] The entire outer surface of the winding is then encapsulated with insulating glue, thus completing the fabrication of a complete laser-cut, stacked, and pressed motor winding.

[0039] The beneficial effects of this application are as follows:

[0040] 1. Suitable for the production of stacked high-power motor windings;

[0041] 2. No harmful waste gas is emitted during the production and preparation process or from the raw materials;

[0042] 3. Achieve low-carbon production throughout the entire process;

[0043] 4. The preparation method is easy to automate the entire process. Attached Figure Description

[0044] Figure 1 This is a flowchart of a method for preparing an electric motor winding according to the present invention; Detailed Implementation

[0045] The specific embodiments of this application will be further described in detail below with reference to the accompanying drawings. These embodiments are only for illustrating this application and are not intended to limit the invention.

[0046] In the description of this invention, it should be noted that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for 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 invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0047] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; 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; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0048] Furthermore, in the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0049] like Figure 1 A method for preparing an electric motor winding includes the following steps 1-21:

[0050] 1. Cutting copper plate blanks: Cut copper plate blanks according to the process dimensions required for preparing winding blanks;

[0051] 2. Copper plate shaping: Uneven copper plate blanks are shaped to achieve the required flatness.

[0052] 3. Visual positioning holes and process holes are cut using laser cutting. The visual positioning holes are cleaned thoroughly to facilitate subsequent visual positioning, identification, and differentiation.

[0053] 4. Deburr and clean any remaining slag adhering to the upper and lower surfaces of the cut surface;

[0054] 5. Conductor segment cutting and UV curing adhesive filling and fixing: The conductor body on the copper plate is divided by laser cutting, and the cut is filled with UV curing adhesive and the conductor body on both sides of the cut is cured and bonded with adhesive, so that the relative position of the divided conductor body is consistent with the visual positioning hole.

[0055] 6. Cut conductor leads and jumper wires: Cut the winding leads or jumper wires according to the requirements of the circuit diagram;

[0056] 7. UV-curable adhesive is used to fill and fix the conductor leads and shorting wires. The cut seams are filled with UV-curable adhesive and the adhesive is cured to bond the conductor leads or shorting wires on both sides of the cut seams, so that the relative positions of the cut conductor leads or shorting wires are consistent with the visual positioning holes.

[0057] 8. UV-curable adhesive undergoes secondary thermal curing; this process achieves the final grouting and fixing effect.

[0058] 9. Remove residual adhesive from the conductor copper plate: Grind and remove any residual adhesive remaining on the surface of the cut copper plate, and ensure that there are no conductive impurities embedded between the conductors cut out of the copper plate.

[0059] 10. Cutting the inner and outer pads of the conductor copper plate: Laser cutting is used to divide the inner and outer pads of the conductor, i.e., the connection points, to form independent electrical connection points;

[0060] 11. Deburr and remove slag and conductive impurities from the pad seams and the upper and lower surfaces;

[0061] 12. Conductor pad pretreatment: Grind and clean the conductor pad connection surface to remove oxide scale, oil, and other substances that are detrimental to welding.

[0062] 13. Apply solder paste by screen printing it onto the pads to ensure a full and rich application of solder paste;

[0063] 14. Solder paste pretreatment of pads: Low-temperature baking and dehydration treatment of solder paste on conductor copper plates;

[0064] 15. Hot pressing of windings and electrical connection of pads: The conductor copper plate and PP sheet that have been pretreated with solder paste are stacked and the inner and outer pads that are connected to each other are aligned. The stacked conductor copper plate and PP sheet are fixed and placed in a vacuum hot press for bonding and pressing of conductor copper plate and PP sheet and solder paste reflow soldering to connect the upper and lower pads at the corresponding positions.

[0065] 16. Visual inspection and quality treatment: Visual inspection is carried out on the pressed and bonded semi-finished windings. If there is solder overflow and sticking or conductive impurities in the gaps between the pads, quality treatment such as laser cleaning is carried out for minor defects.

[0066] 17. Seal the pad connection area with UV-cured adhesive to fill the gap between the inner and outer pads, ensuring the pad position, the strength of the inner and outer rings, and the insulation between the pad connection points;

[0067] 18. Milling and removing inner and outer process edges: Use a CNC milling machine to mill and remove inner and outer process edges, ensuring that there are no sticky copper shavings between the inner and outer pads and that the gaps are clear.

[0068] 19. Pre-treatment of winding leads: Welding and insulation treatment of the phase winding leads of the pressed motor windings;

[0069] 20. Conduct electrical performance testing of windings, including phase winding resistance testing, phase-to-phase insulation testing, and current carrying capacity testing;

[0070] 21. Overall encapsulation: UV-cured adhesive is applied to the outer surface of the entire winding, thus completing the preparation of a complete laser-cut, stacked, and pressed motor winding.

[0071] Specifically, in implementation, the copper plate blank is first cut according to the required winding blank dimensions. Next, the copper plate is shaped to achieve a flatness tolerance of 0.1mm (if the flatness of the blank surface is higher than 0.5mm, resulting in noticeable visual distortion, it will cause significant positional and shape errors in the cutting of conductors and electrical connection points. Verification shows that the flatness tolerance of the copper plate blank is conservatively below 0.1mm, which can control the shape and positional errors of electrical connection points caused by thermal deformation during laser cutting within 0.01-0.02mm). Then, the visual positioning holes and process holes are cut using laser cutting to ensure the integrity of the visual positioning holes and to clean away surrounding impurities and oxide scale for subsequent visual positioning identification and differentiation. Finally, deburring is performed on the cut surfaces. The top and bottom surfaces are cleaned of any remaining slag. Then, conductor segments are cut and fixed with UV-cured adhesive. The conductor body on the copper plate is divided using laser cutting, and the cuts are filled with UV-cured adhesive and then cured to bond the conductor body on both sides of the cut, ensuring the relative position of the divided conductor body is consistent with the visual positioning hole. Next, conductor leads and jumpers are cut according to the circuit diagram. The cuts of the conductor leads and jumpers are then filled and fixed with UV-cured adhesive, ensuring the relative position of the divided conductor leads or jumpers is consistent with the visual positioning hole. Finally, the UV-cured adhesive undergoes a second heat curing process, baking at 110℃ for 6 minutes to achieve the final filling and fixing effect.

[0072] This application has been verified multiple times. The UV-curable adhesive can be cured at 110°C within 6 minutes to achieve high hardness without stickiness, and there is no adhesion to impurities generated in subsequent processes.

[0073] Next, residual adhesive on the surface of the conductor copper plate is removed by grinding. The residual adhesive on the cut copper plate surface is polished and removed, ensuring that there are no conductive impurities embedded between the conductors on the copper plate. Then, the inner and outer pads of the conductor copper plate are cut and the mechanical fixing process holes are cut. The inner and outer pads of the conductor, i.e. the connection points, are laser-cut to form independent electrical connection points. Next, the cut surface is deburred to remove the pad dividing seams and the slag and conductive impurities adhering to the upper and lower surfaces. Finally, the conductor pads are pre-treated by grinding and cleaning the conductor pad connection surfaces to remove oxide scale, oil stains and other substances that are detrimental to welding.

[0074] Subsequently, solder paste was applied with a thickness of 0.2mm (sample verification: after applying 1mm diameter solder paste and reflow soldering, the average solder slump height was 0.16mm). After applying equal amounts of solder paste to the pads of two flat electrical connection points and bonding them together, the spacing was 0.2mm, which meets the 0.5mm requirement. 2 (Based on the above cross-sectional requirements) The stencil is used to screen print solder paste onto the pads to ensure that the solder paste is full and saturated;

[0075] Next, the solder paste on the conductor copper plate undergoes low-temperature baking and dehydration treatment. Then, the conductor copper plate and PP sheet with pre-treated solder paste are stacked and aligned with the inner and outer pads. The stacked conductor copper plate and PP sheet are fixed and placed in a vacuum hot press for bonding and pressing of the conductor copper plate and PP sheet, and reflow soldering of the solder paste to connect the upper and lower pads at the corresponding positions. Next, visual inspection and quality processing are performed. The semi-finished winding that has been pressed and bonded is visually inspected. If there is solder overflow and adhesion or conductive impurities in the gaps between the pads, laser cleaning and other quality processing are performed for minor defects. Finally, the pad connection part is... The process involves sealing the gaps between the inner and outer pads with UV-cured adhesive to ensure proper pad positioning, inner and outer ring strength, and insulation and fixation between pad connection points. Next, a CNC milling machine is used to remove the inner and outer process edges, ensuring no copper shavings adhere between the inner and outer pads and clear gaps. Then, the pressed motor windings undergo phase winding lead welding and insulation treatment. Following this, phase winding resistance, phase-to-phase insulation, and current carrying capacity tests are performed. After passing electrical performance tests, the entire winding is encapsulated, and the outer surface of the winding is sealed with UV-cured adhesive. This completes the fabrication of a laser-cut, stacked, and pressed motor winding.

[0076] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and substitutions can be made without departing from the technical principles of the present invention, and these improvements and substitutions should also be considered within the scope of protection of the present invention.

Claims

1. A method for preparing an electric motor winding, characterized in that, Includes the following steps: S1. For the prefabricated copper plate blank workpiece, complete the conductor segment cutting and insulating glue filling and fixing. The conductor body on the copper plate is divided by laser cutting, and the cut is filled with insulating glue and the conductor body on both sides of the cut is glued and bonded with glue, so that the relative position of the divided conductor body is consistent with the visual positioning hole. S2, conductor lead and jumper wire cutting: cut the winding leads or jumper wires according to the needs of the circuit diagram. S3, Insulation glue is used to fill and fix the conductor leads and short wires. The cut is filled with insulation glue and the glue is cured to bond the conductor leads or short wires on both sides of the cut, so that the relative position of the cut conductor leads or short wires is consistent with the visual positioning hole. S4, cure the insulating adhesive on the workpiece to obtain the final filling and fixing effect; S5, Remove residual adhesive from conductor copper plate: Grind and remove the residual adhesive left on the surface of the cut copper plate to ensure that there are no conductive impurities embedded between the conductors cut out on the copper plate. S6, Cutting the inner and outer pads of the conductor copper plate, laser cutting and dividing the inner and outer pads of the conductor, i.e. the electrical connection points, to form independent electrical connection points; S7, winding hot pressing and electrical connection point connection, multi-layer stacking of conductor copper plate and PP sheet and alignment of internal and external electrical connection points, fixing the stacked conductor copper plate and PP sheet, and placing them in a vacuum hot press for bonding and pressing of conductor copper plate and PP sheet and electrical connection of corresponding upper and lower electrical connection points.

2. The method for preparing a motor winding as described in claim 1, characterized in that, The prefabricated copper plate blank in S1 is obtained through the following steps: the copper plate blank is blanked to obtain the copper plate workpiece, the copper plate workpiece is shaped, the visual positioning holes and process holes are cut on the copper plate, and the copper plate workpiece is deburred. Copper plate workpiece shaping involves shaping uneven copper plate blanks to achieve the required flatness. Visual positioning holes and process holes are cut using laser cutting methods. Visual positioning holes are used for visual positioning recognition and differentiation. Deburring of copper plate workpieces and cleaning of residual molten slag adhering to the cut upper and lower surfaces; The insulating adhesive is a transparent, colorless UV-curable adhesive; Electrical connections are made by reflow soldering or laser welding.

3. The method for preparing a motor winding as described in claim 2, characterized in that, After the copper plate in S1 is shaped, the flatness tolerance shall not exceed 0.1mm.

4. The method for preparing a motor winding as described in claim 1, characterized in that, The secondary thermosetting parameters in S4 are: the insulating adhesive on the workpiece is cured by heating at 110°C within 6 minutes.

5. The method for preparing a motor winding as described in claim 1, characterized in that, Including step S7: Deburr, remove slag and conductive impurities from electrical connection points, seams, and upper and lower surfaces; Conductor pad pretreatment involves grinding and cleaning the conductor pad connection surface to remove oxide scale and oil stains; Apply solder paste by scraping and screen printing it onto the pads to ensure the paste is full and saturated. Solder paste pretreatment of pads involves low-temperature baking and dehydration of the solder paste on the conductor copper plate.

6. The method for preparing a motor winding as described in claim 5, characterized in that, The solder paste is applied in S7, and the stencil thickness is 0.2mm.

7. The method for preparing a motor winding as described in claim 6, characterized in that, Including step S8: The winding is hot-pressed and the pads are electrically connected. The conductor copper plate and PP sheet are stacked and aligned to connect the internal and external electrical connection points. The stacked conductor copper plate and PP sheet are fixed and placed in a vacuum hot press to bond and press the conductor copper plate and PP sheet and connect the upper and lower electrical connection points at the corresponding positions.

8. The method for preparing a motor winding as described in claim 7, characterized in that, Including step S9: Visual inspection and quality control: Visual inspection is performed on the pressed and bonded semi-finished windings. If there are minor defects such as solder overflow and adhesion or conductive impurities in the gaps between the pads, laser cleaning treatment is performed on the minor defects.

9. A method for preparing a motor winding as described in claim 8, characterized in that, Including step S10: The pad connection area is sealed with adhesive, and the gap between the inner and outer pads is filled with insulating adhesive to ensure insulation between the pad position, the inner and outer ring strength, and the pad connection point. The inner and outer process edges are milled and removed by machining, so that there are no sticky copper shavings between the inner and outer pads and the gaps are clear.

10. A method for preparing a motor winding as described in claim 9, characterized in that, Including step S11: Pre-treatment of winding leads: Welding and insulation treatment of phase winding leads of the pressed motor windings; Electrical performance testing of windings includes phase winding resistance testing, phase-to-phase insulation testing, and current carrying capacity testing. The entire winding is then encapsulated with insulating glue, thus completing the fabrication of a laser-cut, stacked, and pressed motor winding.

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