Modularized arc winding PCB disc type motor stator structure

Abstract

The invention discloses a modularized arc winding PCB disc type motor stator structure, which comprises positive PCB modules, negative PCB modules, insulating sheets arranged between two adjacent positive PCB modules and negative PCB modules, and connecting modules used for connecting all the positive PCB modules and negative PCB modules in series. According to the structure provided by the invention, the wiring flexibility, the space utilization rate and the heat dissipation capability of the PCB stator can be improved.

Description

Technical Field

[0001] This invention belongs to the field of motor rotor design, and particularly relates to a modular arc-shaped winding PCB disc motor stator structure. Background Technology

[0002] PCB disc motors are permanent magnet synchronous motors with axial flux. The coreless stator structure based on PCB technology can effectively reduce motor mass and avoid hysteresis and eddy current losses caused by the stator core, eliminate torque pulsation caused by stator slots, and improve motor stability, power density and efficiency.

[0003] Due to limitations in PCB manufacturing processes, single-layer copper foil is relatively thin, necessitating the use of multi-layer PCBs to ensure the current-carrying capacity of the windings. However, multi-layer PCBs are difficult to manufacture, have a high scrap rate, and require numerous buried and blind vias to connect windings in different layers, making maintenance difficult and hindering mass production.

[0004] Once a multilayer PCB is designed, it is difficult to change the number of slots and the internal series and parallel connections. If the motor design needs to be changed, it must be redesigned, and the original motor cannot be reused. Secondly, since the PCB stator requires an external power supply line, existing PCB stators are often non-circular, with irregular shapes such as grooves or protrusions. This effectively increases the outer diameter of the stator, resulting in a waste of PCB wiring space and materials.

[0005] Meanwhile, since the main substrate of PCB is resin, after a long period of operation, heat is easily generated inside the PCB stator with a large number of layers, making it difficult to dissipate heat effectively.

[0006] Patent document CN109995153A discloses a stator structure for a multi-combination adjustable PCB concentrated winding. This structure adopts a double-layer winding method and introduces the concept of "slot" into the coreless PCB stator winding. Each "slot" contains an upper element side of a coil and a lower element side of an adjacent coil. The upper and lower element sides of each "slot" are completely overlapped in the circumferential position and isolated from each other by a PCB insulation layer in the axial position, and are distributed in different PCB wiring layers. Each coil in this stator structure is uniformly distributed in the circumferential direction, and any two adjacent coils are located in different PCB wiring layers. Each coil has a pair of positive and negative output terminals, and each pair of positive and negative output terminals can be connected in series and parallel in various combinations according to different pole-slot combinations in the PCB disc permanent magnet motor design.

[0007] Patent document CN119382378A discloses a modular PCB motor stator winding structure, including: a PCB stator board and a plurality of winding coils disposed thereon, characterized in that the PCB stator board adopts a circular disc structure, the winding coils adopt a wedge structure, and the plurality of winding coils are evenly distributed on the PCB stator board in a circular pattern. Summary of the Invention

[0008] The purpose of this invention is to provide a modular arc-shaped winding PCB disc motor stator structure, which can effectively improve the heat dissipation performance of the stator and at the same time give the motor stator customized attributes.

[0009] To achieve the purpose of this invention, the following technical solution is provided: a modular arc-shaped winding PCB disc motor stator structure, comprising multiple PCB modules, an insulating sheet disposed between two adjacent PCB modules, and a connecting module for connecting all PCB modules in series; The PCB module includes a substrate and an inner interface arranged in a ring along the central region of the substrate and an outer interface arranged along the perimeter edge of the substrate. Each outer interface and the corresponding inner interface are connected by an arc-shaped wire to form an arc-shaped winding. The arc-shaped windings on the same PCB module have the same arc-shaped orientation. The horizontal placement of two adjacent PCB modules is opposite, so that the corresponding arc windings face opposite directions; The insulating sheet is used to cover the arc-shaped conductor, and a clearance opening is provided in the central area. The clearance opening is used to connect the module to the inner interface corresponding to two adjacent PCB modules. The insulating sheet has a second mounting hole on its outer edge, and the substrate has a first mounting hole positioned corresponding to the second mounting hole.

[0010] Specifically, the arc-shaped conductor adopts an integer slot three-phase distributed winding form.

[0011] Specifically, the connection module includes press-fit terminals for embedding inner or outer interfaces and wires.

[0012] Specifically, the conductor is made of flat copper wire or round copper wire.

[0013] Specifically, the press-fit terminal is provided with a multi-segment spring sheet structure.

[0014] Specifically, the spring sheet structure adopts a fisheye spring.

[0015] Specifically, the inner interface and the outer interface are copper-plated through holes, and the ports of the copper-plated through holes are provided with pads for fixing the connection module.

[0016] Specifically, there are multiple second mounting holes, which are arranged in a ring around the center of the insulating sheet.

[0017] Compared with the prior art, the beneficial effects of the present invention are as follows: The modular arc winding design is adopted. The complete stator is composed of several identical arc winding PCBs arranged in opposite directions. The winding structure of each layer in a single PCB is exactly the same. Modular design can effectively reduce the processing and maintenance difficulty and usage cost of the overall PCB. There is no need to use blind or buried vias inside the board layers. If necessary, only the individual PCB that has failed needs to be replaced, without scrapping the entire PCB stator. The space left on the side of the insulating sheet not only allows for flying wires on the same layer of PCB when multiple PCBs are stacked, but also allows for the routing of wires or power lines from any layer in the middle of the PCB while keeping the PCB circular, further improving the flexibility and space utilization of PCB stator routing. By utilizing press-fit terminals and copper-plated through-hole cold connections, as well as soldering connections between wires and pads, the winding series-parallel relationship can be flexibly changed and the number of stator slots can be multiplied according to requirements. Used PCB stators can also be disassembled again and reassembled according to needs, expanding their applicability. The copper-plated through-holes at the ends of the arc-shaped windings can effectively connect the windings in different layers of a single PCB in parallel and conduct the heat inside the PCB to the outside through the through-holes. The pad structure at both ends of the through-holes can also play a certain role in heat dissipation. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of a stator structure for an arc-shaped winding PCB disc motor provided in this embodiment; Figure 2 This is a schematic diagram of the PCB module provided in this embodiment; Figure 3 This is a schematic diagram of the insulating sheet provided in this embodiment; Figure 4 This is a schematic diagram of the installation of the press-fit terminal provided in this embodiment; Figure 5 This is a schematic diagram of the phase arrangement of the first three-phase winding in this embodiment; Figure 6 This is a schematic diagram of the winding arrangement of the unidirectional PCB module provided in this embodiment; Figure 7 This is a schematic diagram of a U-phase single-phase structure provided in this embodiment; Figure 8 This is a schematic diagram of a parallel structure of two-turn U-phase windings in different layers provided in this embodiment; Figure 9 This is a schematic diagram of a two-turn U-phase winding with different layers connected in series, as provided in this embodiment. Figure 10 This is a schematic diagram of the phase arrangement of the second type of three-phase winding provided in this embodiment; Figure 11 This is a schematic diagram of the third type of three-phase winding phase arrangement provided in this embodiment; In the diagram, 1. PCB module; 1-1. Upright PCB module; 1-2. Reverse PCB module; 2. Arc winding; 2-1. Upright arc winding; 2-2. Reverse arc winding; 3. Copper-plated through hole; 4. Solder pad; 5. First mounting hole; 6. Insulating sheet; 7. Second mounting hole; 8. Arc groove; 9. Press-fit terminal; 10. Wire; 10-1. External wire; 10-2. Internal wire. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the 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.

[0020] like Figure 1 and Figure 2 As shown, the PCB module 1 structurally includes an arc-shaped winding 2, copper-plated through-holes 3, pads 4, and a first mounting hole 5. The PCB module 1 has a multi-layer structure, typically 2-6 layers. The arc-shaped windings 2 are evenly distributed on different layers of the PCB module 1. Each end of the arc-shaped winding 2 is provided with a copper-plated through-hole 3, which can connect and conduct to the adjacent arc-shaped windings 2 on each layer of the PCB module 1. The upper and lower ports of the copper-plated through-holes 3 are each provided with pads 4. The first mounting holes 5 are evenly distributed on the outside of the PCB module 1. The insulating sheet 6 is provided with evenly distributed second mounting holes 7 and arc-shaped grooves 8. The projected shape of the arc-shaped grooves 8 is the same as the shape formed by the copper-plated through-holes 3 and the pads 4. The diameter of the copper-plated through-holes 3 matches the selection of the press-fit terminal 9. The shape of the pads 4 can be any shape, such as circular or rectangular.

[0021] PCB module 1 can be divided into upright PCB module 1-1 and reverse PCB module 1-2 according to the horizontal placement method. Similarly, the winding on the upright PCB module 1-1 is a positive arc winding 2-1, and the winding on the reverse PCB module 1-2 is a negative arc winding 2-2.

[0022] This embodiment is a three-phase, eighteen-slot distributed winding stator. Each PCB module 1 should have 2-6 layers of arc-shaped windings 2 with the same vertical projection.

[0023] like Figure 2 As shown, the insulating sheet 6 includes a second mounting hole 7 and an arc-shaped groove 8.

[0024] like Figure 3 As shown, taking the stacking of three PCB modules 1 as an example, the two corresponding copper-plated through holes 3 that need to be connected are cold-connected using press-fit terminals 9. The raised spring structure on the press-fit terminal 9 can make tight contact with the corresponding copper-plated through holes 3 and conduct the two copper-plated through holes 3, thereby conducting the two corresponding arc-shaped windings 2. The press-fit terminal 9 is provided with at least two segments of fisheye or other spring structure. If necessary, terminals with more segments of spring structure can be used to make cross-layer connections of more layers. When multiple PCB modules 1 are stacked, the press-fit terminals 9 should be installed in order from bottom to top. The end height of the press-fit terminal 9 is less than the thickness of the insulating sheet, which allows multiple PCB modules 1 to be installed flat.

[0025] like Figure 4 As shown, a positive PCB module 1-1 and a negative PCB module 1-2 constitute the minimum winding unit. An insulating sheet 6 is needed to separate the two PCB modules 1. The insulating sheet 6 can enhance the insulation performance between the adjacent arc windings 2 of the two PCB modules 1.

[0026] like Figure 5 As shown, two upright PCB modules 1-1 are stacked with an insulating sheet 6, and all the copper-plated windings 3 on the top and bottom are connected one-to-one to achieve a structure with more parallel windings. If it is necessary to connect to a third or more other PCB modules 1, multi-segment press-fit terminals 9 are required.

[0027] More specifically, the arc-shaped winding 2 adopts an integer slot three-phase distributed winding form. A complete winding requires at least one upright PCB module 1-1 and one reverse PCB module 1-2 connected together. The actual stator should be composed of several upright PCB modules 1-1 and reverse PCB modules 1-2 arranged and combined. The insulating sheet 6 needs to be installed between every two PCBs. In practice, the insulating sheet 6 is aligned with the first mounting hole 5 on the PCB module 1 through the second mounting hole 7 and fixed by bolts or other fixing methods, so that the upright PCB module 1-1, the insulating sheet 6, and the reverse PCB module 1-2 are stacked and locked from top to bottom. The arc-shaped winding 2 can be of unequal width.

[0028] Two or more of the upper and lower arc-shaped windings 2 are connected by being inserted into two or more corresponding copper-plated through holes 3 through the press-fit terminal 9; the positive arc-shaped winding 2-1 and the negative arc-shaped winding 2-2 are connected in series end to end through the press-fit terminal 9 to form a closed arc-shaped coil in the projection direction.

[0029] The conductor 10 can be connected to the corresponding winding 2 by welding the pads 4 at different positions, thereby changing the series and parallel connection relationship of the windings; the conductor 10 is a flat copper wire, but a round copper wire can also be used when there is enough space.

[0030] The height of the upper end of the press-fit terminal 9 is less than the thickness of the insulating sheet 6, and the upper end of the press-fit terminal 9 is made of insulating material or has undergone insulation treatment.

[0031] The press-fit terminal 9 is provided with at least two sections of fisheye or other spring structure. The spring structure has a certain elasticity and can fit tightly against the copper-plated through hole 3 and conduct the circuit. The connection between the press-fit terminal 9 and the copper-plated through hole 3 is a detachable cold connection.

[0032] The surface of the pad 4 where the wire 10 is not soldered should be treated with removable insulation.

[0033] The number and arrangement of the first mounting holes 5 must ensure that they correspond one-to-one when the upright PCB module 1-1 and the reverse PCB module 1-2 are stacked.

[0034] like Figure 6 and Figure 7As shown, in Example 1, a minimum winding unit consisting of a positive PCB module 1-1 and a negative PCB module 1-2 is used as an example. The two boards together form a very simple PCB stator. The windings connected end-to-end form a closed arc-shaped winding coil in the projection direction. The entire stator can be divided into three phases. Taking phase U as an example, it can be divided into three parts: U1, U2, and U3, based on the winding arrangement. Each part contains one set of positive arc-shaped winding 2-1 and one set of negative arc-shaped winding 2-2, each occupying a virtual slot position. Therefore, Example 1 is a single-phase 6-slot and three-phase 18-slot PCB stator. Each set of arc-shaped winding 2 contains several turns of copper-clad winding; in this example, it is four turns. In practice, this can be adjusted according to the available area and performance specifications on PCB module 1.

[0035] like Figure 8 As shown, taking two non-adjacent turns of the U phase as an example to illustrate the parallel connection method on the same PCB module 1, except for the four copper-plated through holes 3 on the outside of U3, the other copper-plated through holes 3 at corresponding positions are connected to each other through press-fit terminals 9. Take one upper pad on the outside of one turn of the positive arc winding 2-1 of U3 as the positive potential pad 4U+ of the U phase, and the pad below the corresponding turn of the reverse arc winding 2-2 below U3 as the negative potential pad 4U- of the U phase. The positive potential pad 4U+ and the negative potential pad 4U- of the U phase are respectively soldered to the pad 4 on another turn of the arc winding 2 on the same layer, and are connected by wires 10. The thickness of the wires 10 should be less than that of the insulating sheet 6, and can be placed in the gap between the two PCB modules 1 and the insulating sheet 6. Current flows through the U-phase positive potential pad 4U+ and the upper conductor 10 into the two positive arc windings 2-1 of the same layer as U3. Following the direction indicated by the arrow in the figure, the current flows through the windings of U1 and U2 and then back to the reverse arc winding 2-2 in U3. The left reverse arc winding 2-2 is connected to the U-phase negative potential pad 4U- through the corresponding lower conductor 10. At this time, the current on both turns of the reverse arc winding 2-2 is discharged outward through the U-phase negative potential pad 4U-, realizing the operation of the complete parallel winding.

[0036] like Figure 9As shown, taking two non-adjacent turns of phase U as an example, the winding series connection method between the upright PCB module 1-1 and the reverse PCB module 1-2 is illustrated. Except for the four copper-plated through holes 3 on the outside of U3, the copper-plated through holes 3 at the corresponding positions are connected to each other through press-fit terminals 9. One upper pad on the outside of one turn of the positive arc winding 2-1 of U3 is taken as the positive potential pad 4U+ of phase U, and the pad below the other turn of the reverse arc winding 2-2 below U3 is taken as the negative potential pad 4U- of phase U. An external wire 10-1 is soldered between the upper pad 4 on the outside of the positive arc winding 2-1 on the left side of U3 and the lower pad 4 on the outside of the reverse arc winding 2-2 on the right side of U3, connecting and conducting the positive arc winding 2-1 on the left side of U3 and the reverse arc winding 2-2 on the right side of U3. The external wire 10-1 is on the outside of PCB module 1. Alternatively, the inner conductor 10 can be soldered between the lower outer pad 4 of the left-side positive arc winding 2-1 of U3 and the upper outer pad 4 of the right-side negative arc winding 2-2 of U3. The inner conductor 10 is located between the upper and lower PCB modules 1 and the insulating sheet 6, and is an internal conductor. It should be noted that the external conductor 10-1 and the inner conductor 10-2 do not need to coexist; only one should be soldered depending on the actual situation. Current enters the positive arc winding 2-1 on the right side of U3 through the U-phase positive potential pad 4U+. Following the direction indicated by the arrow in the figure, the current flows through the windings of U1 and U2 and then back to the right-side reverse arc winding 2-2 of U3. The reverse arc winding 2-2 on the right side of U3 is connected to the positive arc winding 2-1 on the U3 side through the external conductor 10-1 or the internal conductor 10-2. The current continues to flow through the windings of U1 and U2 and returns to the left-side reverse arc winding 2-2 of U3. It is then led outward through the U-phase negative potential pad 4U on the reverse arc winding 2-2, thus realizing the operation of the complete parallel winding.

[0037] This series structure can be extended to more sets of PCB module 1 series structures. Simply connect the copper-plated through hole 3 corresponding to the original U-phase negative potential pad 4U- to the copper-plated through hole 3 on the next positive arc winding 2-1 through the press-fit terminal 9 to transfer the current into the next set of closed windings. At this time, the pad 4 on the next positive arc winding 2-1 is equivalent to the U-phase positive potential pad 4U+ in the first set of structures. Refer to the connection method in this series structure to connect the second set. The corresponding U-phase negative potential pad 4U- will also be transferred to the corresponding reverse arc winding 2-2 in the second set. This process can be repeated to stack and connect several sets in series.

[0038] Using the above series-parallel structure, several winding connection forms can be realized. By freely combining and arranging the forward and reverse arrangement forms and sequences of PCB module 1, PCB disc motor stators with different performance can be obtained. It is only necessary to satisfy the principle that the total number of turns of the forward arc winding 2-1 and the reverse arc winding 2-2 in the series and parallel connections are equal.

[0039] like Figure 10 As shown, in Embodiment 2, the windings in Embodiment 1 are re-phased, changing the original 4 turns per slot to 2 turns per slot. The stator then becomes a single-phase 12-slot structure (U and A form one phase, V and B form one phase, and W and C form one phase), and the entire stator is a three-phase 36-slot structure. Similarly, the PCB module 1 of Embodiment 1 can be extended to a stator with 18Q slots (Q is a natural number greater than 0).

[0040] like Figure 11 As shown, the winding arrangement in Embodiment 3 is a stator structure with a minimum of 8 slots for single-phase and a minimum of 24 slots for three-phase. Referring to Embodiments 1 and 2, it can be seen that the winding structure in Embodiment 3 can be extended to a stator with 24Q slots (Q is a natural number greater than 0).

[0041] As can be seen from Embodiments 1, 2, and 3, the winding structure in this application can be extended to a stator structure with 6N slots (N is a natural number greater than 1).

[0042] Furthermore, the terms "upper," "lower," "inner," "outer," "front," and "rear" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. Unless otherwise specifically stated, the relative steps, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of the invention.

[0043] Of course, the above description is only a specific embodiment of the present invention and is not intended to limit the scope of the present invention. All equivalent changes or modifications made to the structure, features and principles described in the claims of the present invention should be included in the scope of the claims of the present invention.

[0044] Finally, it should be noted that the above-described embodiments are merely specific implementations of the present invention, used to illustrate the technical solutions of the present invention, and not to limit it. The scope of protection of the present invention is not limited thereto. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that any person skilled in the art can still modify or easily conceive of changes to the technical solutions described in the foregoing embodiments within the technical scope disclosed in the present invention, or make equivalent substitutions for some of the technical features; and these modifications, changes, or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be covered within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A modular arc-shaped winding PCB disc motor stator structure, characterized in that, It includes multiple PCB modules, as well as insulating sheets placed between two adjacent PCB modules and connecting modules for connecting all PCB modules in series; The PCB module includes a substrate and an inner interface arranged in a ring along the central region of the substrate and an outer interface arranged along the perimeter edge of the substrate. Each outer interface and the corresponding inner interface are connected by an arc-shaped wire to form an arc-shaped winding. The arc-shaped windings on the same PCB module have the same arc-shaped orientation. The horizontal placement of two adjacent PCB modules is opposite, so that the corresponding arc windings face opposite directions; The insulating sheet is used to cover the arc-shaped conductor, and a clearance opening is provided in the central area. The clearance opening is used to connect the module to the inner interface corresponding to two adjacent PCB modules. The insulating sheet has a second mounting hole on its outer edge, and the substrate has a first mounting hole positioned corresponding to the second mounting hole.

2. The modular arc-shaped winding PCB disc motor stator structure according to claim 1, characterized in that, The arc-shaped conductor adopts an integer slot three-phase distributed winding form.

3. The modular arc-shaped winding PCB disc motor stator structure according to claim 1, characterized in that, The connection module includes press-fit terminals for embedding inner or outer interfaces and wires.

4. The modular arc-shaped winding PCB disc motor stator structure according to claim 1, characterized in that, The conductor is made of flat copper wire or round copper wire.

5. The modular arc-shaped winding PCB disc motor stator structure according to claim 3, characterized in that, The press-fit terminal is equipped with a multi-segment spring sheet structure.

6. The modular arc-shaped winding PCB disc motor stator structure according to claim 5, characterized in that, The spring sheet structure adopts a fisheye spring.

7. The modular arc-shaped winding PCB disc motor stator structure according to claim 1, characterized in that, The inner interface and the outer interface are made of copper-plated through holes, and the ports of the copper-plated through holes are provided with pads for fixing the connection modules.

8. The modular arc-shaped winding PCB disc motor stator structure according to claim 1, characterized in that, There are multiple second mounting holes, which are arranged in a ring around the center of the insulating sheet.

Images