A ring-shaped waveform coil winding and a coreless motor

Abstract

This invention relates to the field of motor technology, specifically to a ring-shaped waveform coil winding and a coreless motor. The ring-shaped waveform coil winding includes a wire harness unit, which is wound a plurality of turns along a ring path; the extension trajectory of the wire harness unit alternately bends in a wavy shape towards the inner and outer sides of the ring path; the wire harness unit includes a first segment and a second segment; the first segment and the second segment are alternately connected; the portion of the wire harness unit extending circumferentially along the ring path is the first segment; the portion of the wire harness unit extending radially along the ring path is the second segment; at least a portion of the first segment is stacked along the axial direction of the ring path. This solves the problem of low magnetic field density in the waveform coil winding.

Description

Technical Field

[0001] This invention relates to the field of motor technology, and more specifically, to a ring-shaped waveform coil winding and a coreless motor. Background Technology

[0002] An electric motor is a core power device that converts electrical energy into mechanical energy based on the law of electromagnetic induction. It is widely used in almost all scenarios requiring power drive, including industrial production, transportation, home appliances, and medical equipment. A coreless motor is a special type of motor that eliminates the silicon steel core found in traditional motors. Its core feature is the elimination of hysteresis and eddy current losses caused by the core. Combined with a lightweight winding design, it achieves high efficiency, low loss, lightweight, low inertia, and low vibration and noise operation. Coreless motors have a wide range of applications, such as wheel-side drive in electric passenger vehicles. By integrating the motor directly near the wheel, instead of the long drive chain from the motor to the reducer to the drive shaft in traditional centralized drives, it optimizes vehicle power response, space utilization, and energy consumption. A coreless motor includes a stator and a rotor. The stator typically consists of toroidal coil windings.

[0003] A ring-shaped waveform coil winding is a special type of motor winding with wavy, bent ends, unlike the straight or circular transitions of traditional windings. It is primarily suitable for coreless motors, special asynchronous motors, and other applications with specific requirements for winding shape and space utilization. Its core features are compact structure, high electromagnetic coupling efficiency, and adaptability to complex magnetic field distributions. Waveform coils are typically laid flat with a wavy winding pattern. When a large number of coils are wound, the radial expansion of the coils becomes significant, resulting in a more dispersed magnetic field distribution and consequently, insufficient torque on the motor's output shaft. Improving the density of the magnetic field distribution is a pressing issue that needs to be addressed. Summary of the Invention

[0004] To address the problem of low magnetic field density in waveform coil windings, this invention provides a ring-shaped waveform coil winding and a coreless motor.

[0005] In a first aspect, the present invention provides a ring-shaped waveform coil winding.

[0006] The annular waveform coil winding includes a wire harness unit, which is wound with a number of turns along an annular path; the extension trajectory of the wire harness unit alternately bends towards the inner and outer sides of the annular path in a wavy shape.

[0007] The wiring harness unit includes a first line segment and a second line segment; the first line segment and the second line segment are alternately connected; the portion of the wiring harness unit extending in the circumferential direction along the annular path is the first line segment; the portion of the wiring harness unit extending radially along the annular path is the second line segment; at least a portion of the first line segments are stacked along the axial direction of the annular path.

[0008] In some embodiments, the first line segment includes an outer circle line segment and an inner circle line segment; the outer circle line segment is located at the end of the second line segment pointing to the outside of the loop path; the inner circle line segment is located at the end of the second line segment pointing to the inside of the loop path;

[0009] The outer ring segment includes a first outer segment, a second outer segment, and a third outer segment; the first outer segment corresponds one-to-one with the second outer segment; the first outer segment and the corresponding second outer segment are stacked along the axial direction of the annular path; the second outer segment corresponds to several third outer segments; the second outer segment and the corresponding several third outer segments are arranged in close proximity along the radial direction of the annular path, and the several third outer segments are located on the inner circumference of the arc where the second outer segment is located.

[0010] In some embodiments, the second line segments connected to the first outer layer line segment, the second line segments connected to the second outer layer line segment, and the second line segments connected to the third outer layer line segment are arranged in close succession.

[0011] In some embodiments, the inner ring segment includes a first inner layer segment, a second inner layer segment, and a third inner layer segment; the first inner layer segment corresponds one-to-one with the second inner layer segment; the first inner layer segment and the corresponding second inner layer segment are stacked along the axial direction of the annular path; the first inner layer segment corresponds to a plurality of the third inner layer segments; the first inner layer segment and the corresponding plurality of the third inner layer segments are arranged in close proximity along the radial direction of the annular path, and the plurality of the third inner layer segments are located on the outer periphery of the arc where the first inner layer segment is located.

[0012] In some embodiments, the second line segments connected to the first inner layer line segment, the second line segments connected to the second inner layer line segment, and the second line segments connected to the third inner layer line segment are arranged in close succession.

[0013] In some embodiments, the wire harness unit further includes a first lead and a second lead; the first lead extends radially along the annular path; the second lead extends radially along the annular path.

[0014] In some embodiments, the first line segment further includes a tiling line segment; the tiling line segment and the outer ring line segment are located in the same annular area; there are multiple tiling line segments; the multiple tiling line segments are arranged in close succession along the radial direction of the annular path; the tiling line segment is located between the first lead and the second lead.

[0015] In some embodiments, multiple annular waveform coil windings are stacked along the axial direction of the annular path; the multiple annular waveform coil windings are staggered in their axial projection along the annular path.

[0016] In some embodiments, three annular waveform coil windings are stacked along the axial direction of the annular path; the first and second segments of the annular waveform coil winding located in the middle position are located in the same reference plane; the reference plane is perpendicular to the axis of the annular path; the first segments of the annular waveform coil windings located on both sides are bent away from the first segment of the annular waveform coil winding located in the middle position.

[0017] In a second aspect, the present invention provides a coreless motor, the coreless motor comprising the annular waveform coil winding of any embodiment in the first aspect.

[0018] The coreless motor includes:

[0019] A stator assembly, the stator assembly comprising the annular waveform coil winding as described in any of the first aspects;

[0020] The rotor assembly includes a permanent magnet that passes through the interior of the annular waveform coil winding.

[0021] To address the problem of low magnetic field density in waveform coil windings, this invention offers the following advantages:

[0022] 1. By stacking the first segments of the annular waveform coils distributed in the circumferential direction in the axial direction, the density of the magnetic field distribution is increased, thereby increasing the torque output of the motor.

[0023] 2. Since the annular waveform coil winding is wound around the corresponding coil winding fixture, the coil is wound from the outside to the inside. The first outer layer segment and the second outer layer segment are stacked in the axial direction, and the first inner layer segment and the second inner layer segment are stacked in the axial direction. During the winding of the outermost and innermost coils, the coil winding fixture can be used to realize the stacking of part of the first segment, and avoid the problem of interference between the winding positions of the coils that may be caused by stacking in other parts. The winding is more convenient and neat.

[0024] 3. Multiple annular waveform coil windings are stacked in an axially staggered manner to increase the strength of the generated magnetic field and further increase the density of the magnetic field distribution, thereby increasing the torque output of the motor. Attached Figure Description

[0025] Figure 1 A schematic diagram of the structure of an annular waveform coil winding according to one embodiment is shown;

[0026] Figure 2 It shows Figure 1 A partial structural schematic diagram of the loop-shaped waveform coil winding in the image;

[0027] Figure 3 A schematic diagram of a stack of multiple annular waveform coil windings is shown in one embodiment.

[0028] Reference numerals: 10. Wire harness unit; 11. First line segment; 111. Outer ring line segment; 1111. First outer layer line segment; 1112. Second outer layer line segment; 1113. Third outer layer line segment; 112. Inner ring line segment; 1121. First inner layer line segment; 1122. Second inner layer line segment; 1123. Third inner layer line segment; 113. Laying line segment; 12. Second line segment; 13. First lead wire; 14. Second lead wire. Detailed Implementation

[0029] The present disclosure will now be discussed with reference to several exemplary embodiments. It should be understood that these embodiments are discussed only to enable those skilled in the art to better understand and thus implement the present disclosure, and are not intended to imply any limitation on the scope of the disclosure.

[0030] As used herein, the term "comprising" and its variations are to be interpreted as open-ended terms meaning "including but not limited to". The term "based on" is to be interpreted as "at least partially based on". The terms "one embodiment" and "an embodiment" are to be interpreted as "at least one embodiment". The term "another embodiment" is to be interpreted as "at least one other embodiment". The terms "upper", "lower", "left", "right", "front", "rear", "top", "bottom", "inner", "outer", "vertical", "horizontal", "lateral", "longitudinal", etc., indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings. These terms are primarily for the purpose of better describing this application and its embodiments and are not intended to limit the indicated devices, elements, or components to having a specific orientation or being constructed and operated in a specific orientation. Furthermore, some of the above terms may be used to indicate other meanings besides orientations or positional relationships; for example, the term "upper" may in some cases indicate a dependency or connection relationship. Those skilled in the art can understand the specific meaning of these terms in this application according to the specific circumstances. In addition, the terms "installed", "set up", "equipped with", "connected", and "linked" should be interpreted broadly. For example, it can be a fixed connection, a detachable connection, or an integral structure; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, or an internal connection between two devices, elements, or components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances. Furthermore, the terms "first," "second," etc., are mainly used to distinguish different devices, elements, or components (the specific types and structures may be the same or different), and are not used to indicate or imply the relative importance or quantity of the indicated devices, elements, or components. Unless otherwise stated, "a plurality of" means two or more.

[0031] An electric motor is a core power device that converts electrical energy into mechanical energy based on the law of electromagnetic induction. A coreless motor is a special type of motor that eliminates the silicon steel core found in traditional motors. Coreless motors have a wide range of applications, such as wheel-side drive in electric passenger vehicles. A coreless motor consists of a stator and a rotor. The stator typically consists of wave-shaped coil windings. A ring-shaped wave-shaped coil winding is a special type of motor coil winding. When a large number of coils are wound, the radial expansion of the coils becomes large, resulting in a more dispersed magnetic field distribution, which in turn leads to insufficient torque on the motor's output shaft. To address the problem of low magnetic field density in wave-shaped coil windings, this embodiment provides a ring-shaped wave-shaped coil winding and a coreless motor.

[0032] Example 1:

[0033] This embodiment provides a ring-shaped waveform coil winding, such as Figure 1 As shown, the annular waveform coil winding includes a wire harness unit 10. The wire harness unit 10 is wound with a number of turns along the annular path; the extension trajectory of the wire harness unit 10 alternately bends towards the inner and outer sides of the annular path in a wavy shape;

[0034] The wiring harness unit 10 includes a first segment 11 and a second segment 12; the first segment 11 and the second segment 12 are alternately connected; the portion of the wiring harness unit 10 extending circumferentially along the annular path is the first segment 11; the portion of the wiring harness unit 10 extending radially along the annular path is the second segment 12; at least a portion of the first segment 11 is stacked axially along the annular path. This increases the density of the magnetic field distribution, thereby increasing the torque output of the motor.

[0035] It is worth noting that the radial extension of the second segment 12 means that the distance between the extension line of the second segment 12 and the center of the loop path is less than a threshold. This ensures that the magnetic field generated by the waveform coil is uniformly distributed circumferentially and coaxially with the axis of the waveform coil.

[0036] In this embodiment, the number of turns of the wire harness unit 10 wound along the annular path is set to 3 turns, 4 turns, or 5 turns, preferably 4 turns. The annular waveform coil winding also includes a tightening unit, which can be tape. By wrapping it around the outside of the adjacent first wire segments 11 or the adjacent second wire segments 12, the annular waveform coil winding is tightened, thereby completing the processing.

[0037] Furthermore, such as Figure 1 As shown, the first segment 11 includes an outer loop segment 111 and an inner loop segment 112. The average diameter of the arc containing the outer loop segment 111 is larger than the average diameter of the arc containing the inner loop segment 112. The winding is wavy, with the outer loop segments 111 spaced apart circumferentially; the inner loop segments 112 spaced apart circumferentially; and the outer loop segments 111 and inner loop segments 112 alternating circumferentially. At least a portion of the first segments 11 are stacked axially along the annular path. Specifically, at least a portion of the first segments 11 can be an outer loop segment 111, an inner loop segment 112, or both outer loop segments 111 and inner loop segments 112.

[0038] The outer loop segment 111 is located at the end of the second loop segment 12 pointing to the outside of the loop path; the inner loop segment 112 is located at the end of the second loop segment 12 pointing to the inside of the loop path; that is, the waveform coil is distributed alternately along the circumference in sequence with the inner loop segment 112, the second loop segment 12, the outer loop segment 111, the second loop segment 12, and the inner loop segment 112.

[0039] The outer ring segment 111 includes a first outer layer segment 1111, a second outer layer segment 1112, and a third outer layer segment 1113; here, "including" means that there are multiple outer ring segments 111, which are radially divided from the outside to the inside into the first outer layer segment 1111, the second outer layer segment 1112, and the third outer layer segment 1113. The first outer layer segment 1111 corresponds one-to-one with the second outer layer segment 1112; the first outer layer segment 1111 and the corresponding second outer layer segment 1112 are stacked along the axial direction of the annular path. The second outer layer segment 1112 corresponds to several third outer layer segments 1113; the second outer layer segment 1112 and the corresponding several third outer layer segments 1113 are arranged in close proximity along the radial direction of the annular path, and the several third outer layer segments 1113 are located on the inner circumference of the arc where the second outer layer segment 1112 is located.

[0040] In this embodiment, the third outer layer segments 1113 can be one, two, or three, preferably two. In other embodiments, the central angle of the inner loop segment 112 on the loop path is larger than that of the outer loop segment 111, which makes the magnetic field generated by the coil winding stronger.

[0041] Furthermore, such as Figure 1 As shown, the second segment 12 connected to the first outer segment 1111, the second segment 12 connected to the second outer segment 1112, and the second segment 12 connected to the third outer segment 1113 are arranged in close succession. In this way, the second segments 12 connected to the outer segment 111 are arranged in close succession along the radial direction of the circular path.

[0042] Furthermore, such as Figure 1 As shown, the inner circle segment 112 includes a first inner layer segment 1121, a second inner layer segment 1122, and a third inner layer segment 1123. The inner circle segment 112 is also distributed along a circular path, from the inside out as the first inner layer segment 1121, the second inner layer segment 1122, and the third inner layer segment 1123. The first inner layer segment 1121 corresponds one-to-one with the second inner layer segment 1122; the first inner layer segment 1121 and its corresponding second inner layer segment 1122 are stacked axially along the circular path. The first inner layer segment 1121 corresponds to several third inner layer segments 1123; the first inner layer segment 1121 and its corresponding several third inner layer segments 1123 are arranged radially and closely attached to each other along the circular path, with the several third inner layer segments 1123 located on the outer periphery of the arc containing the first inner layer segment 1121.

[0043] The first inner layer segment 1121 and the corresponding second inner layer segment 1122 are stacked axially along the annular path as follows: Figure 2As shown, the second inner layer segment 1122 is located below the first inner layer segment 1121. This allows the second inner layer segment 1122 to be pressed down when winding the second to last inner layer segment 112, so that the third inner layer segment 1123 and the second inner layer segment 1122 are located on different planes. Then, the first inner layer segment 1121 is wound on the second inner layer segment 1122, so that the first inner layer segment 1121 and several third inner layer segments 1123 are located on the same plane, simplifying the winding method and realizing a compact structure of wire harness stacking.

[0044] Furthermore, such as Figure 1 As shown, the second line segment 12 connected to the first inner line segment 1121, the second line segment 12 connected to the second inner line segment 1122, and the second line segment 12 connected to the third inner line segment 1123 are arranged in close succession, so that the second line segment 12 connected to the inner circle line segment 112 can be arranged in close succession on the radial side of the ring path.

[0045] Furthermore, such as Figure 1 As shown, the wiring harness unit 10 also includes a first lead 13 and a second lead 14; the first lead 13 extends radially along the annular path; the second lead 14 extends radially along the annular path. The first lead 13 and the second lead 14 extend radially along the annular path for a certain length, exceeding the first outer layer segment 1111, and form a certain gap between the first lead 13 and the second lead 14. This provides space for the installation of the power supply and makes the installation of the power supply more convenient.

[0046] To avoid interference between the first lead 13 and the second lead 14 and the wound first segment 11 or second segment 12 along the axial direction of the loop path, which would cause winding difficulties, the winding process is typically started from the outer ring and gradually moved towards the inner ring. The first outer layer segment 1111 and the second outer layer segment 1112 are stacked axially, so that the second outer layer segment 1112 and several third outer layer segments 1113 are on the same plane. This simplifies the winding process. For example, the first outer layer segment 1111 is first pressed down and fixed using a tooling fixture, and then the second outer layer segment 1112 and the third outer layer segment 1113 are wound sequentially above the first outer layer segment 1111, completing the winding of the outer ring segment 111. Similarly, stacking the first inner layer segment 1121 and the corresponding second inner layer segment 1122 along the axial direction of the loop path also avoids interference between the inner ring segment 112 and the first lead 13 and the second lead 14 during the winding process, and simplifies the winding process.

[0047] Furthermore, such as Figure 1As shown, the first segment 11 also includes a tiled segment 113. The tiled segment 113 and the outer ring segment 111 are located in the same annular region; there are multiple tiled segments 113; the multiple tiled segments 113 are arranged in close succession along the radial direction of the annular path; the tiled segment 113 is located between the first lead 13 and the second lead 14. The number of turns of the tiled segment 113 is one less than that of the outer ring segment 111, that is, the waveform coil is broken at the tiled segment 113, thereby leading out the first lead 13 and the second lead 14, so that the power supply can be connected to the circuit of the waveform coil.

[0048] In other embodiments, the tiling segment 113 may be located on the same loop path as the inner loop segment 112.

[0049] Furthermore, such as Figure 3 As shown, multiple annular waveform coil windings are stacked axially along the annular path; the magnetic field strength formed by stacking multiple waveform coil windings is significantly increased compared to a single waveform coil winding. The axial projections of the multiple annular waveform coil windings along the annular path are staggered. The stagger angle between the axial projections of adjacent waveform coils on the annular path can be set to 8°~12°, thus reducing the space occupied by the stacked waveform coil windings. Furthermore, the staggered arrangement, combined with the wavy outer coil segment 111 and inner coil segment 112, reduces the difficulty of axial stacking and increases the concentration of the magnetic field distribution. Preferably, the stagger angle between the axial projections of adjacent waveform coils on the annular path can be set to 10°.

[0050] Furthermore, three annular waveform coil windings are stacked axially along the annular path; the first segment 11 and the second segment 12 of the annular waveform coil winding located in the middle position are located in the same reference plane; the reference plane is perpendicular to the axis of the annular path; the first segment 11 of the annular waveform coil windings located on both sides is bent away from the first segment 11 of the annular waveform coil winding located in the middle position. This allows the annular waveform coil windings located on both sides to avoid overlap with the annular waveform coil winding located in the middle position, further reducing the stacking difficulty while increasing the concentration of the magnetic field distribution.

[0051] Example 2:

[0052] This embodiment provides a coreless motor, which includes a stator assembly and a rotor assembly. The stator assembly includes any of the annular waveform coil windings described in Embodiment 1; the rotor assembly includes a permanent magnet, which is disposed inside the annular waveform coil winding. When the annular waveform coil winding is energized, the current distribution in the annular waveform winding interacts with the air gap magnetic field of the rotor permanent magnet, efficiently converting electrical energy into mechanical energy and transmitting it to the motor's output shaft. Simultaneously, the coreless design eliminates core losses, achieving high-efficiency and low-vibration operation.

[0053] Those skilled in the art will understand that the above embodiments are specific examples of implementing this disclosure, and in practical applications, various changes can be made in form and detail without departing from the scope of this disclosure.

Claims

1. A ring-shaped waveform coil winding, characterized in that, The annular waveform coil winding includes a wire harness unit, which is wound with a number of turns along an annular path; the extension trajectory of the wire harness unit alternately bends towards the inner and outer sides of the annular path in a wavy shape. The wire harness unit includes a first line segment and a second line segment; the first line segment and the second line segment are alternately connected; the portion of the wire harness unit extending along the circumferential direction of the annular path is the first line segment; The portion of the wire harness unit extending radially along the annular path is the second line segment; at least a portion of the first line segments are stacked along the axial direction of the annular path. The first line segment includes an outer circle line segment and an inner circle line segment; the outer circle line segment is located at the end of the second line segment pointing to the outside of the loop path; the inner circle line segment is located at the end of the second line segment pointing to the inside of the loop path; The outer ring segment includes a first outer layer segment, a second outer layer segment, and a third outer layer segment; the first outer layer segment corresponds one-to-one with the second outer layer segment; the first outer layer segment and the corresponding second outer layer segment are stacked along the axial direction of the annular path; the second outer layer segment corresponds to several third outer layer segments; the second outer layer segment and the corresponding several third outer layer segments are arranged in close proximity along the radial direction of the annular path, and the several third outer layer segments are located on the inner circumference of the arc where the second outer layer segment is located; The second line segments connected to the first outer layer line segment, the second line segments connected to the second outer layer line segment, and the second line segments connected to the third outer layer line segment are arranged in close succession.

2. The annular waveform coil winding according to claim 1, characterized in that, The inner circle segment includes a first inner layer segment, a second inner layer segment, and a third inner layer segment; the first inner layer segment corresponds one-to-one with the second inner layer segment; the first inner layer segment and the corresponding second inner layer segment are stacked along the axial direction of the annular path; the first inner layer segment corresponds to several third inner layer segments; the first inner layer segment and the corresponding several third inner layer segments are arranged in close proximity along the radial direction of the annular path, and the several third inner layer segments are located on the outer periphery of the arc where the first inner layer segment is located.

3. The annular waveform coil winding according to claim 2, characterized in that, The second line segments connected to the first inner layer line segment, the second line segments connected to the second inner layer line segment, and the second line segments connected to the third inner layer line segment are arranged in close succession.

4. The annular waveform coil winding according to claim 1, characterized in that, The wire harness unit further includes a first lead and a second lead; the first lead extends radially along the annular path; the second lead extends radially along the annular path.

5. A ring-shaped waveform coil winding according to claim 4, characterized in that, The first line segment further includes a tiling line segment; the tiling line segment and the outer ring line segment are located in the same annular area; there are multiple tiling line segments; the multiple tiling line segments are arranged in close succession along the radial direction of the annular path; the tiling line segment is located between the first lead and the second lead.

6. The annular waveform coil winding according to claim 1, characterized in that, Multiple annular waveform coil windings are stacked along the axial direction of the annular path; the multiple annular waveform coil windings are staggered in their axial projection along the annular path.

7. A ring-shaped waveform coil winding according to claim 6, characterized in that, Three annular waveform coil windings are stacked along the axial direction of the annular path; the first and second segments of the annular waveform coil winding located in the middle position are located in the same reference plane; the reference plane is perpendicular to the axis of the annular path; the first segments of the annular waveform coil windings located on both sides are bent away from the first segment of the annular waveform coil winding located in the middle position.

8. A coreless motor, characterized in that, The coreless motor includes: A stator assembly comprising the annular waveform coil winding as described in any one of claims 1-7; The rotor assembly includes a permanent magnet that passes through the interior of the annular waveform coil winding.

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