Wire winding method suitable for motor coil
By adopting thin-plate wire structure and innovative winding methods, the problems of large gaps and high consumption of insulating varnish in motor coil manufacturing have been solved, and the coil volume and winding time have been optimized.
Patent Information
- Application Number
- CN202511362888.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-23
- Publication Date
- 2025-11-21
AI Technical Summary
Existing motor coil manufacturing processes suffer from problems such as the inability to eliminate copper wire gaps, low space utilization, long winding time, and high consumption of insulating varnish.
The conductor uses a thin plate structure and an innovative winding method is designed to fold the conductor and fit it tightly against the wire groove, reducing gaps and improving space utilization. The winding process is optimized through the design of the folding and winding sections.
It improves the space utilization of the coil, reduces the coil volume and winding time, and reduces the consumption of insulating varnish.
Smart Images
Figure CN120999983A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of coil manufacturing, and in particular to a method for winding wires suitable for motor coils. Background Technology
[0002] In the production process of motors, enameled wires such as copper wire are usually wound around the coil and a winding machine is used for winding. This technical solution has the following problems: (1) There are unavoidable gaps between the copper wires, the space utilization rate cannot be further improved, and the volume of the coil cannot be further reduced; (2) The copper wire is very long and requires a long winding time; (3) The surface area of the copper wire is relatively large, so the consumption of insulating varnish is also relatively large. Summary of the Invention
[0003] To address the aforementioned problems in existing technologies, this invention provides a wire winding method suitable for motor coils. It replaces cylindrical copper wires with thin-plate wires and designs an innovative winding method, which significantly improves the space utilization of the coil, reducing not only the coil volume but also the winding time and the amount of insulating varnish consumed.
[0004] The technical solution of the present invention is as follows:
[0005] A method for winding a conductor suitable for motor coils, wherein the conductor is a thin plate structure and can be bent; the surface of the conductor is covered with an insulating material; the two surfaces of the conductor perpendicular to the thickness direction are respectively called the upper surface and the lower surface; a plane perpendicular to the thickness direction is made, called the projection plane; the conductor is projected onto the projection plane, and the two longer sides of the projection are called the conductor edges;
[0006] The steps of the method are as follows:
[0007] S1. Draw two straight lines on the upper surface of the conductor that meet the following conditions, which are called broken line 1 and broken line 2 respectively:
[0008] (1-1) The broken line 1 is not parallel to the edge of the conductor;
[0009] (1-2) The second broken line 2 is parallel to the first broken line 1;
[0010] (1-3) Among the two intersection points of the broken line 1 and the edge of the conductor, select one intersection point located between the broken line 1 and the broken line 2. Draw a straight line perpendicular to the edge of the conductor through this intersection point, which is called the gap edge 3.
[0011] (1-4) Among the two intersection points of broken line 2 and the edge of the conductor, select one intersection point located between broken line 1 and broken line 2. Draw a straight line perpendicular to the edge of the conductor through this intersection point, which is called the gap edge 4.
[0012] (1-5) The first edge of the gap 3 and the second edge of the gap 4 do not coincide. When viewed on the projection plane, the first edge of the gap 3 is located between the first line of the fold line 1 and the second edge of the gap 4, and the second edge of the gap 4 is located between the first edge of the gap 3 and the second line of the fold line 2.
[0013] The conductor between fold line 1 and fold line 2 is called fold segment 5, and the conductors on both sides of the fold segment are called winding segment 1 6 and winding segment 2 7, respectively.
[0014] S2. Using line 1 as the axis, fold the wire 180 degrees; using line 2 as the axis, fold the wire 180 degrees.
[0015] S3. Fold section 5 is pressed tightly against the wire groove 8, and the edges of the wires of winding section 1 6 and winding section 2 7 are perpendicular to the central axis of the wire groove 8.
[0016] S4. Perform a winding operation on winding section 6 and winding section 7 around the central axis of the wire groove 8 to obtain a complete coil.
[0017] Furthermore, the angle between the broken line 1 and the edge of the conductor is 45 degrees.
[0018] Furthermore, in step S2, the upper or lower surface of the folded segment 5 is used as the interface, and the first winding segment 6 and the second winding segment 7 are located on the same side of the interface.
[0019] Furthermore, the distance between gap edge 3 and gap edge 4 is equal to the thickness of the conductor.
[0020] Furthermore, a plane is constructed perpendicular to the upper surface of the conductor, and the distance from this plane to the edge of the gap 3 is equal to the distance to the edge of the gap 4; this plane divides the conductor into two parts of equal length.
[0021] Furthermore, the material of the wire is copper or aluminum.
[0022] The beneficial technical effects of this invention are as follows:
[0023] (1) Compared with the prior art, the present invention can improve the space utilization of the coil; under the premise of the same performance index, the present invention can reduce the volume of the coil.
[0024] (2) The conductor used in this invention is a thin plate structure, which is equivalent to combining many copper wires together. Therefore, the length is much shorter than that of copper wires, and the winding time is also much less.
[0025] (3) Under the premise of the same performance index, the surface area of the conductor of the present invention is smaller than that of the copper wire, so the surface coating of the conductor is also less than that of the latter. Attached Figure Description
[0026] Figure 1 This is a schematic diagram of wire folding;
[0027] Figure 2 This is a schematic diagram of the coil winding;
[0028] Figure 3 This is a schematic diagram of copper wire winding.
[0029] In the figure, the correspondence between the component names and the attached drawing numbers is as follows: 1. Broken line one; 2. Broken line two; 3. Gap edge one; 4. Gap edge two; 5. Folded section; 6. Winding section one; 7. Winding section two; 8. Wire groove. Detailed Implementation
[0030] The present invention will now be described in detail with reference to the accompanying drawings and embodiments. Obviously, the described embodiments are merely some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.
[0031] like Figures 1-3 As shown, the conductor used in this embodiment is an aluminum wire with a thin plate cross-section and is bendable; the surface of the conductor is covered with insulating varnish. The two surfaces of the conductor perpendicular to the thickness direction are called the upper surface and the lower surface, respectively; a plane perpendicular to the thickness direction is called the projection plane; the conductor is projected onto the projection plane, and the two longer edges of the projection are called the conductor edges.
[0032] The winding method of the embodiment is as follows:
[0033] S1, such as Figure 1 As shown, two straight lines are drawn on the upper surface of the conductor that meet the following conditions, and are called broken line 1 and broken line 2, respectively:
[0034] (1-1) The angle between the broken line 1 and the edge of the conductor is 45 degrees;
[0035] (1-2) The second broken line 2 is parallel to the first broken line 1;
[0036] (1-3) Among the two intersection points of the broken line 1 and the edge of the conductor, select one intersection point located between the broken line 1 and the broken line 2. Draw a straight line perpendicular to the edge of the conductor through this intersection point, which is called the gap edge 3.
[0037] (1-4) Among the two intersection points of broken line 2 and the edge of the conductor, select one intersection point located between broken line 1 and broken line 2. Draw a straight line perpendicular to the edge of the conductor through this intersection point, which is called the gap edge 4.
[0038] (1-5) Slit edge 3 and slit edge 4 do not coincide, and the distance between them is equal to the thickness of the conductor. When viewed on the projection plane, slit edge 3 is located between broken line 1 and slit edge 4, and slit edge 4 is located between slit edge 3 and broken line 2.
[0039] (1-6) Construct a plane perpendicular to the upper surface of the conductor, and the distance from the plane to the edge of the gap 3 is equal to the distance to the edge of the gap 4; the plane divides the conductor into two parts of equal length.
[0040] The conductor between fold line 1 and fold line 2 is called fold segment 5, and the conductors on both sides of the fold segment are called winding segment 1 6 and winding segment 2 7, respectively.
[0041] S2. Fold the conductor 180 degrees with fold line 1 as the axis; fold the conductor 180 degrees with fold line 2 as the axis. With the upper or lower surface of folded segment 5 as the interface, winding segment 6 and winding segment 7 are located on the same side of the interface.
[0042] S3, such as Figure 2 As shown, the folded section 5 is tightly attached to the groove 8, and the edges of the wires of the first winding section 6 and the second winding section 7 are perpendicular to the central axis of the groove 8.
[0043] S4. Perform a winding operation on winding section 6 and winding section 7 around the central axis of the wire groove 8 to obtain a complete coil.
[0044] Figure 3 This is a schematic diagram of the winding of a circular wire in a traditional coil. From Figure 3 It can be seen that there are gaps between the wires, which cannot be eliminated. The space utilization rate of the wire coil can be simplified to the ratio of the area of a regular hexagon to the area of its inscribed circle. Assuming the radius of the wire (i.e., the inscribed circle) is R, then the side length of the regular hexagon is:
[0045]
[0046] The area of the regular hexagon is:
[0047]
[0048] Space utilization rate:
[0049]
[0050] After adopting the wire winding method of this invention, there are almost no gaps between the wires, and the space utilization rate is approximately 1. Therefore, this invention can improve the space utilization rate of the coil by about 9%. This means that, under the premise of the same performance indicators, this invention can reduce the coil volume by about 9% and shorten the winding ends, which can effectively reduce costs.
[0051] To analyze the consumption of insulating varnish, 100 circular wires were used as the analysis object. The cross-sectional area of the 100 circular wires is:
[0052] S 铜 =100πR 2
[0053] If we simplify the cross-section of the wire used in the embodiment to a rectangle with length L and width 2R, then we have:
[0054]
[0055] The ratio of the cross-sectional perimeter of the conductor used in the embodiment to the cross-sectional perimeter of 100 circular conductors is:
[0056]
[0057] Therefore, the surface area of the conductor used in the embodiment is reduced by about 49% compared to the surface area of 100 circular conductors, and the consumption of insulating varnish is naturally reduced by about 49%.
[0058] Although the embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the specification and embodiments. They can be applied to various fields suitable for the present invention. For those skilled in the art, and for those of ordinary skill in the art, various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention. Therefore, the present invention is not limited to the specific details without departing from the general concept defined by the claims and their equivalents.
Claims
1. A method for winding wires suitable for motor coils, characterized in that: The conductor is a thin plate structure and can be bent; the surface of the conductor is covered with insulating material; the two surfaces of the conductor perpendicular to the thickness direction are called the upper surface and the lower surface, respectively; a plane perpendicular to the thickness direction is called the projection plane; the conductor is projected onto the projection plane, and the two longer sides of the projection are called the conductor edges; The steps of the method are as follows: S1. Draw two straight lines on the upper surface of the conductor that meet the following conditions, which are called broken line one (1) and broken line two (2) respectively: (1-1) The broken line (1) is not parallel to the edge of the conductor; (1-2) The second broken line (2) is parallel to the first broken line (1); (1-3) Among the two intersection points of the broken line (1) and the edge of the conductor, select one intersection point located between the broken line (1) and the broken line (2). Draw a straight line perpendicular to the edge of the conductor through this intersection point, which is called the gap edge (3). (1-4) Among the two intersection points of the second broken line (2) and the edge of the conductor, select one intersection point located between the first broken line (1) and the second broken line (2). Draw a straight line perpendicular to the edge of the conductor through this intersection point, which is called the second gap edge (4). (1-5) The first edge of the gap (3) and the second edge of the gap (4) do not coincide. When viewed on the projection plane, the first edge of the gap (3) is located between the first line (1) and the second edge of the gap (4), and the second edge of the gap (4) is located between the first edge of the gap (3) and the second line (2). The conductor between the first fold line (1) and the second fold line (2) is called the folded segment (5), and the conductors on both sides of the folded segment are called the first winding segment (6) and the second winding segment (7), respectively. S2. Using line 1 (1) as the axis, fold the conductor 180 degrees; using line 2 (2) as the axis, fold the conductor 180 degrees. S3. Place the folded section (5) tightly against the groove (8), and the wire edges of the first winding section (6) and the second winding section (7) are perpendicular to the central axis of the groove (8); S4. Around the central axis of the wire groove (8), perform a winding operation on winding section one (6) and winding section two (7) to obtain a complete coil.
2. The wire winding method for motor coils according to claim 1, characterized in that, The angle between the broken line (1) and the edge of the conductor is 45 degrees.
3. The wire winding method for motor coils according to claim 1, characterized in that: In step S2, the upper or lower surface of the folded segment (5) is used as the interface, and the first winding segment (6) and the second winding segment (7) are located on the same side of the interface.
4. The wire winding method for motor coils according to claim 1, characterized in that, The distance between gap edge one (3) and gap edge two (4) is equal to the thickness of the conductor.
5. The wire winding method for motor coils according to claim 1, characterized in that: Draw a plane perpendicular to the upper surface of the conductor, and the distance from the plane to the first (3) edge of the gap is equal to the distance to the second (4) edge of the gap; the plane divides the conductor into two parts of equal length.
6. The wire winding method for motor coils according to claim 1, characterized in that, The material of the conductor is copper or aluminum.