Hollow cup winding and its winding method, application, hollow cup motor

Abstract

The present application relates to the technical field of electric machines, in particular to a hollow cup winding, a winding method, an application and a hollow cup electric machine. The hollow cup winding is wound by carbon nanotube (CNT) wire, which can meet the demand of lightweight and high power density of electric machines, and is mainly applied to electric machines, such as radial and axial windings. Since the winding is made of carbon nanotube (CNT) wire, it can meet the demand of weight reduction in high-demand occasions, such as drive motors applied in the field of aerospace. The hollow cup electric machine integrates hollow cup radial windings and axial windings wound by carbon nanotube (CNT) wire, which not only obtains CNT windings meeting the requirements of mechanical strength and electrical insulation performance, and hollow cup electric machines integrating axial and radial windings, but also significantly improves the power density and torque density of the electric machine, so as to solve the problems existing in the prior art.

Description

Technical Field

[0001] This invention relates to the field of motor technology, and in particular to a hollow cup winding, its winding method, application, and hollow cup motor. Background Technology

[0002] Currently, research on motor materials technology focuses primarily on magnetic materials, especially the rapid development of rare-earth permanent magnet materials in recent years, which has spurred the emergence of high-performance permanent magnet motors. However, research and application of coil conductor materials are scarce. The future direction of motor development is lightweighting and high power density; however, existing motor windings mostly use copper wire, which cannot meet the demands for lightweighting and high power density.

[0003] Furthermore, current coreless motors, considering that excessive weight will affect power density, generally only have one of the axial winding and radial winding. As the requirements for torque density of motors increase, existing coreless motors can no longer meet the requirements. Summary of the Invention

[0004] The purpose of this invention is to provide a hollow cup winding, its winding method, application, and a hollow cup motor. The hollow cup winding is made of carbon nanotube (CNT) wire, which can meet the requirements of lightweight motor and high power density. The hollow cup motor integrates the hollow cup winding and axial winding made of carbon nanotube (CNT) wire, which not only obtains CNT winding that meets the requirements of mechanical strength and electrical insulation performance, but also a hollow cup motor that integrates axial and radial windings, but also significantly improves the power density and torque density of the motor, thereby solving the problems existing in the prior art.

[0005] To achieve the above objectives, the present invention provides the following solution:

[0006] On one hand, the present invention provides a hollow cup winding, which is a hollow cylindrical winding formed by sequentially arranging and bonding three-phase windings and then winding them, wherein:

[0007] Each phase winding consists of two hollow cup windings and a single winding coil.

[0008] Both hollow cup windings of any phase winding are individually wound using carbon nanotube wires.

[0009] On the other hand, the present invention proposes a method for winding the above-mentioned hollow cup winding, comprising:

[0010] Step 1: Using carbon nanotube wires, each phase winding is wound on the winding skeleton. The two hollow cup windings of each phase winding are wound continuously as single winding coils, so that each phase winding has only two ends.

[0011] Step 2: Arrange the wound three-phase windings in sequence and then glue and fix them to form a flat semi-finished product of the three-phase windings;

[0012] Step 3: The flat semi-finished product of the three-phase winding is wound onto the cylindrical frame, and then bonded, potted, dried and cured. After that, the three-phase winding is removed from the cylindrical frame to obtain the hollow cup winding.

[0013] In some implementations, in step 1, before winding each phase winding on the winding frame, the carbon nanotube wire is first made into a self-adhesive enameled wire.

[0014] In some implementations, in step 1, the winding frame used is a rhombus frame, and two rhombus frames are symmetrically arranged to form two individual winding coils of the hollow cup winding in each phase winding.

[0015] Furthermore, this invention proposes an application of the aforementioned hollow cup winding in an electric motor.

[0016] In another aspect, the present invention proposes a hollow cup motor, comprising a stator assembly, a rotor assembly, a sensor, an axial winding, and a housing end cover, wherein:

[0017] The stator assembly includes a stator housing, a stator core, and a hollow cup winding as described above. The stator core is fixedly sleeved inside the stator housing, and the hollow cup winding is fixedly sleeved inside the stator core. The stator housing, the stator core, and the hollow cup winding are coaxial, and the two ends of the hollow cup winding extend out of the two ends of the stator core, respectively.

[0018] The housing end cap is disposed at one end of the stator housing, and a bearing seat is disposed at the other end of the stator housing;

[0019] The rotor assembly includes a rotor shaft and a rotor magnet ring. The rotor shaft is coaxially inserted into the hollow cup winding. One end of the rotor shaft passes through the housing end cover and is rotatably engaged with the housing end cover via a bearing. The other end of the rotor shaft passes through the bearing seat and is rotatably engaged with the bearing seat via a bearing. The rotor magnet ring is fixedly sleeved on the outside of the rotor shaft and is located between the rotor shaft and the hollow cup winding.

[0020] The axial winding is disposed on the side of the bearing housing away from the rotor magnet ring and is insulated from the bearing housing; the rotor shaft passes through the center of the axial winding.

[0021] The sensor includes a Hall encoder, a circuit, a Hall encoder magnet, and an encoder end cover. The encoder end cover is located at the end of the bearing housing away from the rotor magnet ring. The Hall encoder and the circuit are integrated to form an encoder PCB. The encoder PCB is fixed to the inside of the encoder end cover and faces the axial winding. The Hall encoder magnet is mounted on the rotor shaft and is located between the encoder PCB and the axial winding.

[0022] In some embodiments, the axial winding includes a plurality of circumferentially distributed axial winding individual winding coils, and any one of the axial winding individual winding coils is wound with carbon nanotube wires.

[0023] In some embodiments, a de-weighting ring is respectively fitted on the outer side of both ends of the rotor magnet ring on the rotor shaft, and the two de-weighting rings respectively abut against the end faces of both ends of the rotor magnet ring.

[0024] In some embodiments, the two ends of the hollow cup winding extend out of the two ends of the stator core by the same length.

[0025] In some embodiments, the stator core and the stator housing, the hollow cup winding and the stator core, and the rotor shaft and the rotor magnet ring are all bonded and fixed together.

[0026] In some embodiments, the axial winding is fixed to the bearing housing by adhesive bonding.

[0027] The present invention achieves the following technical effects compared to the prior art:

[0028] The hollow cup winding proposed in this invention is made of carbon nanotube (CNT) wire, which can meet the requirements of lightweight and high power density in motors and is widely used in motors, such as as radial and axial windings. CNT wire has high conductivity, especially single-walled carbon nanotubes, which have higher conductivity than metallic copper. Furthermore, CNT material has a lower density than metallic materials. Therefore, CNT wire is superior to metallic wire materials such as copper and aluminum in both conductivity and density. The hollow cup winding prepared in this way can meet the needs of applications with high weight reduction requirements, such as drive motors used in the aerospace field.

[0029] Currently, there are no reports of integrating axial and radial windings in a coreless motor. Because the windings in this invention are made with CNT wires, they are lightweight. Therefore, adding an axial winding to the existing radial coreless motor windings has little impact on the motor weight. At the same time, it can make full use of the inner space at the end of the motor encoder and the end magnetic flux of the Hall encoder magnet. Therefore, the coreless motor of this invention integrates both radial and axial windings made of carbon nanotube (CNT) wires. This not only provides CNT windings that meet the requirements of mechanical strength and electrical insulation performance, but also a coreless motor that integrates axial and radial windings, and can significantly improve the power density and torque density of the motor. Attached Figure Description

[0030] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0031] Figure 1 This is a schematic diagram of the structure of the hollow cup motor disclosed in an embodiment of the present invention;

[0032] Figure 2 This is a schematic diagram of the product structure of the hollow cup winding disclosed in an embodiment of the present invention;

[0033] Figure 3 This is a schematic diagram of the structure of a single winding coil in a hollow cup winding disclosed in an embodiment of the present invention;

[0034] Figure 4 This is a schematic diagram of the structure of each phase (single phase) winding in the hollow cup winding disclosed in an embodiment of the present invention;

[0035] Figure 5 This is a schematic diagram of the unfolded state structure of the hollow cup winding disclosed in an embodiment of the present invention;

[0036] Figure 6 This is a schematic diagram of the structure of the hollow cup winding wound on the cylindrical frame disclosed in an embodiment of the present invention;

[0037] Figure 7 This is a schematic diagram of the assembly structure of the axial winding on the bearing housing disclosed in an embodiment of the present invention;

[0038] Figure 8 for Figure 7 Top view;

[0039] Figure 9 This is a schematic diagram of the structure of a single winding coil in the axial winding disclosed in an embodiment of the present invention;

[0040] Figure 10 This is a schematic diagram of the structure of a single winding coil in an axial winding disclosed in an embodiment of the present invention, wound on a winding mold;

[0041] Figure 11 for Figure 10 Top view;

[0042] Figure 12 This is a schematic diagram of the winding mold disclosed in an embodiment of the present invention;

[0043] Figure 13 This is a schematic diagram of the structure of the base for winding each phase (single phase) of a hollow cup winding, as disclosed in an embodiment of the present invention.

[0044] Figure 14 This is a schematic diagram of the winding skeleton used for winding each phase (single phase) of a hollow cup winding, as disclosed in an embodiment of the present invention.

[0045] Figure 15 This is a schematic diagram of the assembly of the winding frame and base for winding each phase (single phase) of a hollow cup winding, as disclosed in an embodiment of the present invention.

[0046] In the diagram, the attached figure is labeled: 100, Hollow Cup Motor;

[0047] 1. Stator housing; 2. Stator core; 3. Hollow cup winding; 31. Single-phase winding; 32. Single coil of hollow cup winding; 4. Bearing housing; 5. Bearing 1; 6. Encoder PCB; 7. Lead wire; 8. Encoder end cover; 9. Hall encoder magnet; 10. Spacer sleeve; 11. Axial winding; 111. Single coil of axial winding; 12. Insulating potting compound 1; 13. De-weighting ring 1; 14. Rotor shaft; 15. Rotor magnet ring; 16. De-weighting ring 2; 17. Insulating potting compound 2; 18. Bearing 2; 19. Housing end cover; 20. Retaining ring;

[0048] 200. Cylindrical skeleton;

[0049] 300. Winding die;

[0050] 400. Base; 401. Frame mounting hole; 402. Enamelled wire start fixing hole; 403. Enamelled wire end fixing hole;

[0051] 500. Winding frame. Detailed Implementation

[0052] 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. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0053] One of the objectives of this invention is to provide a hollow cup winding, its winding method, and its application. The hollow cup winding is made of carbon nanotube (CNT) wire, which can meet the requirements of lightweight motors and high power density, thereby solving the problems existing in the prior art.

[0054] Another objective of this invention is to provide a hollow cup motor that integrates a hollow cup winding made of carbon nanotube (CNT) wires and an axial winding. This not only provides a CNT winding that meets the requirements for mechanical strength and electrical insulation performance, but also a hollow cup motor that integrates axial and radial windings. Furthermore, it can significantly improve the power density and torque density of the motor, thereby solving the problems existing in the prior art.

[0055] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0056] Example 1

[0057] This embodiment proposes a hollow cup winding 3 based on carbon nanotube (CNT) wires, such as... Figures 2-5 As shown, it is a hollow cylindrical winding formed by sequentially arranging, bonding, and winding three-phase windings. Each phase winding (i.e., each single-phase winding 31) includes two hollow cup windings and individual winding coils 32. The two hollow cup windings and individual winding coils 32 of each phase winding are continuously wound using carbon nanotube wires.

[0058] The winding method for the hollow cup winding 3 is as follows:

[0059] Step 1: Carbon nanotube (CNT) wires are fabricated into self-adhesive enameled wires, hereinafter referred to as CNT enameled wires. Taking a 3-phase motor with one pair of magnetic poles in the rotor magnet ring 15, and each stator phase (i.e., any single-phase winding 31) consisting of two stator coils (i.e., single hollow cup winding coils 32), for a total of 6 stator coils in 3 phases, one base 400 and two winding frames 500 are used to fabricate the hollow cup winding 3. The winding frames 500 are mounted on the base 400, and there are two winding frames 500. Then, single-phase windings 31 are wound on the winding frames 500 continuously without cutting the CNT enameled wire. Each phase winding has only two ends, thus reducing the wiring within the single-phase winding 31 and improving the electrical performance of the winding. For example, Figure 15 As shown, the winding frame 500 is rhomboid in shape, and the two winding frames 500 are arranged symmetrically. Each phase winding is formed based on this shape. Figure 4 As shown, a single winding coil 32 comprises two hollow cup windings. The winding bobbin 500 serves as a support for the winding, ensuring that the overall dimensions are met.

[0060] Step 2: After all three-phase windings (6 hollow cup windings, each winding coil 32) are wound, arrange them as follows: Figure 5 As shown, the six hollow cup windings are arranged with individual winding coils 32, fixed with adhesive, and then pressed together.

[0061] Step 3: As Figure 6 As shown, the result obtained in step 2, as... Figure 5 The three-phase windings, as shown, are bonded together and wound onto a cylindrical frame 200, the diameter of which is the inner diameter of the stator core 2. The three-phase windings are evenly bonded along the cylindrical frame 200, placed in a tooling for potting, dried and cured, and then the windings are detached to obtain the desired result. Figure 2 The radial hollow cup winding of the hollow cup motor 100 shown.

[0062] The aforementioned hollow cup winding 3 is mostly used in motors, such as as a radial winding. Because it is wound with carbon nanotube (CNT) wires, it can meet the requirements of applications with high weight reduction needs, such as drive motors used in the aerospace field.

[0063] Example 2

[0064] like Figure 1 As shown, this embodiment proposes a hollow cup motor 100 based on radial and axial windings made of carbon nanotube (CNT) wires. The hollow cup motor 100 is an integrated radial and axial hollow cup motor. The hollow cup motor 100 includes a motor body and an electronic driver. The electronic driver can orderly switch the current flowing to each phase winding in the stator assembly according to feedback from a rotor position sensor, thereby generating a rotating magnetic field on the stator. This magnetic field attracts the rotor permanent magnet (i.e., the rotor magnetic ring 15) to rotate continuously. Specifically:

[0065] like Figure 1 As shown, the motor body includes a stator assembly, a rotor assembly, a sensor, an axial winding 11, and a housing end cover 19. Wherein:

[0066] The stator assembly includes a stator housing 1, a stator core 2, and a hollow cup winding 3. The stator core 2 is installed inside the stator housing 1. The stator housing 1 is a cylindrical housing, and the stator core 2 is a hollow cylindrical core. The stator housing 1 and the stator core 2 are fitted with a clearance. During assembly, DG-3 high-temperature resistant adhesive is applied to the outer circular surface of the stator core 2, and then it is pushed into the stator housing 1. Then, the stator housing 1 and the stator core 2 are placed in a temperature chamber to allow the adhesive to cure, thereby achieving adhesive fixation of the stator core 2 inside the stator housing 1.

[0067] The hollow cup winding 3 is installed inside the inner ring of the stator core 2. The hollow cup winding 3 is a hollow cylindrical shape. During assembly, DG-3 high temperature resistant adhesive is applied to the outer surface of the hollow cup winding 3, and then it is pushed into the stator core 2. At the same time, tooling is used to ensure that the two ends of the hollow cup winding 3 extend a certain length from the two ends of the stator core 2. Then, the stator housing 1, the stator core 2 and the hollow cup winding 3 are placed in a temperature chamber to cure the adhesive, thereby achieving the adhesive fixation of the hollow cup winding 3 in the stator core 2.

[0068] In some feasible implementations, it is preferable that the lengths of the hollow cup winding 3 extending from both ends of the stator core 2 are the same, and preferably the lengths of each end are 2mm to 3mm.

[0069] Hollow cup winding 3 is the radial main winding of the motor. The internal winding connections and external lead connections are generally made according to the drawing requirements. The three-phase wires of hollow cup winding 3 are connected in a star configuration. After the tail ends of the three-phase wires are welded together, an insulating tube is fitted externally. Leads are welded to the beginning ends of the three-phase wires (each phase coil of the hollow cup winding has two ends, namely the beginning end and the end end; this is common knowledge in this field and will not be elaborated here). The welded areas are fitted with insulating tubes. Then, DG-3 high-temperature resistant adhesive is used to insulate and pot the two ends of hollow cup winding 3, forming insulating potting body 12 and insulating potting body 27 at the two ends of hollow cup winding 3, respectively. During the potting process of insulating potting body 12 and insulating potting body 27, the end and inner diameter dimensions of insulating potting body 12 and insulating potting body 27 are ensured to meet the drawing requirements by special tooling.

[0070] The rotor assembly includes a rotor shaft 14, a rotor magnet ring 15, a first bearing 5, a second bearing 18, a first de-weighting ring 13, and a second de-weighting ring 16. For example... Figure 1 As shown, the rotor magnet ring 15 is fitted onto the outside of the rotor shaft 14 with a clearance fit. During assembly, anaerobic adhesive is applied to the outer surface of the rotor shaft 14 and then inserted into the rotor magnet ring 15. After the rotor magnet ring 15 is fitted into the corresponding position on the rotor shaft 14, the rotor magnet ring 15 and the rotor shaft 14 are placed in a temperature chamber to allow the adhesive to cure, thereby achieving adhesive fixation between the rotor magnet ring 15 and the rotor shaft 14. The rotor magnet ring 15 and the rotor shaft 14 are coaxial. The rotor magnet ring 15 can be equipped with one or more pairs of magnetic poles as needed.

[0071] On the rotor shaft 14, a first de-weighting ring 13 and a second de-weighting ring 16 are respectively fitted on the outer sides of both ends of the rotor magnet ring 15, such as... Figure 1 As shown, the second de-weighting ring 16 and the first de-weighting ring 13 are respectively close to the left and right end faces of the rotor magnet ring 15. Both the first de-weighting ring 13 and the second de-weighting ring 16 are clearance-fitted with the rotor shaft 14. During assembly, the inner mating surfaces of the second de-weighting ring 16 and the first de-weighting ring 13 are coated with epoxy resin and then fitted onto the rotor shaft 14, respectively close to the left and right end faces of the rotor magnet ring 15. Then, the first de-weighting ring 13, the rotor shaft 14, the rotor magnet ring 15, and the second de-weighting ring 16 are placed in a temperature chamber to cure the resin, thereby fixing the first de-weighting ring 13 and the second de-weighting ring 16 on the rotor shaft 14. The purpose of placing the first de-weighting ring 13 and the second de-weighting ring 16 at both ends of the rotor magnet ring 15 is for de-weighting during dynamic balancing tests of the rotor.

[0072] Bearing 5 and bearing 18 are respectively mounted on the rotor shaft 14 near its two ends. Figure 1 As shown, bearing 5 and de-weighting ring 13 are located at the same end of rotor shaft 14. Bearing 5 is located on the side of de-weighting ring 13 away from rotor magnet ring 15 and is close to the end face of de-weighting ring 13. Correspondingly, bearing 18 and de-weighting ring 16 are located at the same end of rotor shaft 14. Bearing 18 is located on the side of de-weighting ring 16 away from rotor magnet ring 15 and is close to the end face of de-weighting ring 16. Both bearing 5 and bearing 18 have a transition fit with rotor shaft 14. During assembly, the inner rings of bearing 5 and bearing 18, with epoxy resin, are pressed into rotor shaft 14 and rest against the end faces of de-weighting ring 13 and de-weighting ring 16, respectively. Finally, bearing 5, bearing 18, de-weighting ring 13, rotor shaft 14, rotor magnet ring 15, and de-weighting ring 16 are placed in a temperature chamber to cure the resin, thereby fixing the inner rings of bearing 5 and bearing 18 on rotor shaft 14.

[0073] The sensor is the aforementioned rotor position sensor, which includes a Hall encoder, circuit, Hall encoder magnet 9 and encoder end cover 8. The Hall encoder and circuit are integrated on a PCB board to form encoder PCB 6, and the Hall encoder magnet 9 is mounted on the rotor shaft 14.

[0074] like Figure 1 As shown, the entire rotor assembly is inserted into the hollow cup winding 3 of the stator assembly. A housing end cover 19 is provided at the left end of the stator housing 1 (this housing end cover 19 is located at the same end as the second bearing 18 and the second de-weighting ring 16). The left end of the rotor shaft 14 passes through the through hole in the center of the housing end cover 19 and is rotatably engaged with the housing end cover 19 via the second bearing 18. Figure 1As shown, bearing 18 is integrally embedded in the through hole at the center of the housing end cover 19, and the outer ring of bearing 18 is fixed with the inner wall of the through hole by interference fit or adhesive bonding. After the rotor assembly and stator assembly are assembled, the outer surface of the cylindrical rotor magnet ring 15 is in clearance fit with the inner wall of the hollow cup winding 3.

[0075] like Figure 1 As shown, a bearing housing 4 is provided at the end of the stator housing 1 furthest from the housing end cover 19. Both the bearing housing 4 and the housing end cover 19 can be welded to the stator housing 1. For example, after the rotor assembly is assembled into the stator assembly, the bearing housing 4 and the housing end cover 19 can be welded to both ends of the stator housing 1 using laser welding. The right end of the rotor shaft 14 passes through a through hole in the center of the bearing housing 4 and rotates with the bearing housing 4 via a bearing 5. Figure 1 As shown, bearing 5 is integrally embedded in the through hole at the center of bearing housing 4, and the outer ring of bearing 5 is fixed to the inner wall of the through hole by interference fit or adhesive bonding. The housing end cap 19 and bearing housing 4 can respectively axially limit the two ends of the rotor magnet ring 15. Insulating potting body 12 and insulating potting body 17 are respectively arranged against the inner end faces of bearing housing 4 and housing end cap 19, as detailed below. Figure 1 As shown.

[0076] The axial winding 11 is installed at the end of the bearing housing 4 furthest from the rotor assembly. During installation, after the axial winding 11 is fitted onto the right end of the rotor shaft 14, it is adhered to the end face of the bearing housing 4 with epoxy insulating adhesive. The thickness of the insulating adhesive layer is 0.15mm~0.2mm, and the adhesive layer must be continuous to ensure that the insulation between the axial winding 11 and the bearing housing 4 meets the requirements. The axial winding 11 is also star-connected. The tail ends of the three phase wires are welded together and then fitted with insulating tubes. The lead wires are welded to the first end, and the welded parts are fitted with insulating tubes, followed by insulating potting treatment.

[0077] like Figure 1 As shown, the bearing housing 4 is inserted into the right end of the stator housing 1 and is clearance-fitted with the stator housing 1. The two can be fixed by laser welding after assembly.

[0078] The spacer sleeve 10 with epoxy adhesive is inserted into the right end of the rotor shaft 14 and rests against the end face of the bearing 5 away from the rotor assembly; after the epoxy adhesive cures, the spacer sleeve 10 and the rotor shaft 14 can be bonded and fixed. At this time, the spacer sleeve 10 is located in the inner ring of the axial winding 11.

[0079] The encoder PCB 6 is glued to the encoder end cover 8. The encoder end cover 8 is installed at the end of the bearing housing 4 away from the stator housing 1. After adjusting the axial clearance between the encoder end cover 8 and the bearing housing 4, the retaining ring 20 is installed. The encoder end cover 8 serves as the right end cover of the entire motor, with a through hole in its center through which the right end of the rotor shaft 14 passes. The leads 7 of the hollow cup winding 3, the leads 7 of the axial winding 11, and the leads of the encoder PCB 6 are all encased in an insulating tube and led out from the side outlet of the bearing housing 4.

[0080] Install the encoder end cover on the bearing housing 4, adjust the axial clearance, and install the retaining ring 20; finally, laser weld the joint between the encoder end cover 8 and the bearing housing 4 to complete the motor body installation.

[0081] In some feasible implementations, the hollow cup winding 3 is wound with carbon nanotube (CNT) wire, and the axial winding 11, as an auxiliary winding of the motor, is also wound with carbon nanotube (CNT) wire. Wherein:

[0082] The winding method for hollow cup winding 3 is as follows:

[0083] Step 1: Carbon nanotube (CNT) wires are fabricated into self-adhesive enameled wires, hereinafter referred to as CNT enameled wires. Taking a 3-phase motor with one pair of magnetic poles in the rotor magnet ring 15, and each stator phase (i.e., any single-phase winding 31) consisting of two stator coils (i.e., single hollow cup winding coils 32), for a total of 6 stator coils in 3 phases, one base 400 and two winding frames 500 are used to fabricate the hollow cup winding 3. The winding frames 500 are mounted on the base 400, and there are two winding frames 500. Then, single-phase windings 31 are wound on the winding frames 500 continuously without cutting the CNT enameled wire. Each phase winding has only two ends, thus reducing the wiring within the single-phase winding 31 and improving the electrical performance of the winding. For example, Figure 15 As shown, the winding frame 500 is rhomboid in shape, and the two winding frames 500 are arranged symmetrically. Each phase winding is formed based on this shape. Figure 4 As shown, a single winding coil 32 comprises two hollow cup windings. The winding bobbin 500 serves as a support for the winding, ensuring that the overall dimensions are met.

[0084] Step 2: After all three-phase windings (6 hollow cup windings, each winding coil 32) are wound, arrange them as follows: Figure 5 As shown, the six hollow cup windings are arranged with individual winding coils 32, fixed with adhesive, and then pressed together.

[0085] Step 3: As Figure 6 As shown, the result obtained in step 2, as... Figure 5The three-phase windings, as shown, are bonded together and wound onto a cylindrical frame 200, the diameter of which is the inner diameter of the stator core 2. The three-phase windings are evenly bonded along the cylindrical frame 200, placed in a tooling for potting, dried and cured, and then the windings are detached to obtain the desired result. Figure 2 The radial hollow cup winding of the hollow cup motor 100 shown.

[0086] The winding method for axial winding 11 is as follows:

[0087] The axial winding 11 is mounted on the outside of the bearing housing 4. The axial winding 11 is a three-phase winding, with two individual axial winding coils 111 per phase, for a total of six individual axial winding coils 111. The structure of each individual axial winding coil 111 is as follows: Figure 9 As shown, in any axial winding 11, each individual winding coil 111 uses carbon nanotube (CNT) wires. Figures 10-12 The winding is made on the winding mold 300 shown. After the six axial winding individual winding coils 111 of the axial winding 11 are wound, they are evenly installed on the outside of the bearing housing 4. The contact surfaces between the outer end face of the bearing housing 4 and the six axial winding individual winding coils 111 are coated with insulating varnish for insulation treatment. Each phase coil is wired as required, and then the lead wire is connected and led out of the motor together with the three-phase lead wire of the hollow cup winding 3.

[0088] like Figure 9 and Figure 10 As shown, the winding mold 300 includes a rectangular base and a winding post perpendicular to the rectangular base. The winding post is an arc-shaped rod with a fan-shaped cross-section. Based on this, the overall outline of the axial winding individual winding coil 111 is a fan-shaped ring. In the axial winding 11, the six axial winding individual winding coils 111 are evenly distributed in a circle with the axis of the bearing seat 4 as the center.

[0089] The hollow cup motor winding of the present invention includes both a hollow cup winding 3 and an axial winding 11. The above-described method of using CNT wire to make a hollow cup motor winding can ensure that the resulting winding is made into an integral coil.

[0090] In the hollow cup winding 3 and the axial winding 11, the carbon nanotube (CNT) conductors are coated with an insulating varnish and a self-adhesive layer to form self-adhesive enameled wire. The winding frame 500 is mounted on the base 400. The number of winding frames 500 is the same as the number of individual winding coils 32 in each phase winding. Then, a single-phase winding 31 is formed by winding on the winding frame 500. The enameled wire is self-adhesive and continuously wound without cutting the conductor. Each phase winding has only two ends, thus forming a continuous integral winding, thereby eliminating the electrical connection of the individual windings and improving the high voltage withstand performance of the winding.

[0091] Existing motors primarily use copper enameled wire for their windings. Due to copper's high density, the windings constitute a significant portion of the motor's weight, making weight reduction difficult. This invention, however, uses CNT wire to wind the motor windings. CNT wire has a density 1 / 7 that of copper, achieving both weight reduction and increased power density.

[0092] CNT wires have high conductivity, especially single-walled carbon nanotubes, which have higher conductivity than metallic copper. Furthermore, CNT materials have a lower density than metallic materials. Therefore, CNT wires are superior to metallic wire materials such as copper and aluminum in terms of both conductivity and density. Hollow cup windings and / or axial windings prepared from CNTs can meet the needs of applications with high weight reduction requirements, such as drive motors used in the aerospace field.

[0093] Furthermore, there are currently no reports of integrating axial and radial windings in a coreless motor. Since the present invention uses CNT wire to wind the windings, which are lightweight, adding an axial winding to the existing radial coreless winding has little impact on the motor weight. At the same time, it can make full use of the inner space at the end of the motor encoder and the end magnetic flux of the Hall encoder magnet. Therefore, the present invention integrates the axial and radial coreless windings into the coreless motor 100, which not only provides CNT windings that meet the requirements of mechanical strength and electrical insulation performance, but also a coreless motor that integrates axial and radial windings, but also significantly improves the power density and torque density of the motor.

[0094] It should be understood that the structures, proportions, sizes, etc., depicted in the accompanying drawings are merely for illustrative purposes to aid those skilled in the art and to facilitate understanding. They are not intended to limit the scope of the invention and therefore have no substantial technical significance. Any modifications to the structure, changes in proportions, or adjustments to size, without affecting the effectiveness and objectives of the invention, should still fall within the scope of the technical content disclosed herein. Furthermore, the terms "upper," "lower," "left," "right," "middle," and "one" used in this specification are merely for clarity and not intended to limit the scope of the invention. Changes or adjustments to their relative relationships, without substantially altering the technical content, should also be considered within the scope of the invention's implementation.

[0095] Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this invention. Furthermore, those skilled in the art will recognize that, based on the ideas of this invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this invention.

Claims

1. A method of winding a hollow cup winding, characterized in that, The hollow cup winding is a hollow cylindrical winding formed by sequentially arranging and bonding three-phase windings and winding, wherein: any one-phase winding comprises two hollow cup winding single winding coils; any one-phase winding is continuously wound by carbon nanotube wires; the winding method comprises: Step 1: winding each phase winding on the winding framework by using carbon nanotube wires, and continuously winding two hollow cup winding single winding coils of each phase winding, so that each phase winding has only first and last two ends; the winding framework used is a rhombic framework, and two rhombic frameworks are symmetrically arranged to form two hollow cup winding single winding coils in each phase winding; Step 2: sequentially arranging and bonding the wound three-phase windings to form a flat semi-finished product of the three-phase windings; Step 3: winding the flat semi-finished product of the three-phase windings on a cylindrical framework, bonding and potting, and then taking out the three-phase windings from the cylindrical framework after drying and curing to obtain the hollow cup winding.

2. The method of winding a hollow cup winding as defined in claim 1, characterized in that, In step 1, before winding each phase winding on the winding framework, the carbon nanotube wire is made into a self-adhesive enameled wire.

3. Application of the hollow cup winding prepared by the winding method of the hollow cup winding of claim 1 in a motor.

4. A hollow cup motor, characterized by The motor comprises a stator assembly, a rotor assembly, a sensor, an axial winding and a housing end cover, wherein: the stator assembly comprises a stator housing, a stator core and a hollow cup winding prepared by the winding method of the hollow cup winding of claim 1, the stator core is fixedly sleeved in the stator housing, the hollow cup winding is fixedly sleeved in the stator core, the stator housing, the stator core and the hollow cup winding are coaxial, and the two ends of the hollow cup winding respectively extend out of the two ends of the stator core; the housing end cover is arranged at one end of the stator housing, and the other end of the stator housing is provided with a bearing seat; the rotor assembly comprises a rotor shaft and a rotor magnetic steel ring, the rotor shaft is coaxially arranged in the hollow cup winding, one end of the rotor shaft penetrates through the housing end cover and is rotationally connected with the housing end cover through a bearing, the other end of the rotor shaft penetrates through the bearing seat and is rotationally connected with the bearing seat through a bearing, and the rotor magnetic steel ring is fixedly sleeved outside the rotor shaft and located between the rotor shaft and the hollow cup winding; the axial winding is arranged on the side of the bearing seat away from the rotor magnetic steel ring and is insulated from the bearing seat, and the rotor shaft penetrates through the center of the axial winding; the sensor comprises a Hall encoder, a circuit, a Hall encoder magnetic steel and an encoder end cover, the encoder end cover is arranged at one end of the bearing seat away from the rotor magnetic steel ring, the Hall encoder and the circuit are integrated to form an encoder PCB, the encoder PCB is fixed to the inner side of the encoder end cover and faces the axial winding, and the Hall encoder magnetic steel is sleeved on the rotor shaft and located between the encoder PCB and the axial winding.

5. A hollow cup machine according to claim 4, characterized in that The axial winding comprises a plurality of circumferentially distributed axial winding single winding coils, and any axial winding single winding coil is wound by a carbon nanotube wire.

6. A hollow cup machine according to claim 4 or 5, characterized in that Two weight-removing rings are respectively sleeved outside both ends of the rotor magnetic steel ring on the rotor shaft, and the two weight-removing rings respectively abut against the end faces of both ends of the rotor magnetic steel ring.

7. A hollow cup machine according to claim 4 or 5, characterised in that, The lengths of the hollow cup winding protruding from both ends of the stator core are the same.

8. A hollow cup machine according to claim 4 or 5, characterized in that The stator core and the stator shell, the hollow cup winding and the stator core, and the rotor shaft and the rotor magnetic steel ring are all adhesively fixed; The axial winding is adhesively fixed on the bearing seat by insulation glue.

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