Motor rotor winding method
By using a single-layer lap winding method and a winding design with uneven turn distribution, the problems of wire swelling and wire ejection in permanent magnet DC motors were solved, the winding process was optimized, and the motor performance and noise stability were improved.
Patent Information
- Application Number
- CN202411201147.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-08-29
- Publication Date
- 2026-03-10
AI Technical Summary
In the existing technology, the winding design of permanent magnet DC motors leads to the risk of wire swelling and wire breakage, and the use of drip paint treatment is not allowed due to environmental protection, safety and cost factors.
A single-layer lap winding method is adopted, with each winding including N upper coil sides and N lower coil sides. The number of turns is designed to be unevenly distributed and located in different slots. The outer winding has fewer turns than the inner winding, which improves the problem of wire expansion.
It reduces the risk of wire breakage, optimizes the winding process, reduces imbalance and heat loss, and improves motor performance and noise stability.
Smart Images
Figure CN121643374A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to electric motors, and more specifically to a method for winding an electric motor rotor. Background Technology
[0002] To provide high torque, the winding design of permanent magnet DC motors needs to meet the requirements of high torque output. This results in tightly packed windings, leading to wire bulging and a risk of wire breakage. Taking a four-pole, ten-slot rotor with a double-flying winding design as an example, with ten windings of equal turns, each winding includes 39 turns. After the rotor is wound to the last coil, the enamel wire accumulates severely at the slot opening, causing wire bulging. Figure 1 As shown.
[0003] The current solution is rotor varnish dripping. However, factories may decide against varnish dripping based on various considerations such as environmental protection, safety, cost, efficiency, technological updates, quality control, industry standards, or equipment facilities. In such cases, alternative solutions are needed to address the issues of winding coil swelling and the risk of wire breakage. Summary of the Invention
[0004] To address the problems of wire swelling in the prior art, the present invention provides a method for winding a motor rotor.
[0005] According to the motor rotor winding method of the present invention, it is a single-layer lap winding, each winding includes N upper coil sides and N lower coil sides, the N upper coil sides are located in one slot, and the N lower coil sides are located in another slot separated by at least one pitch, each slot includes upper and lower coil sides belonging to two windings respectively; for each slot, the winding wound first is located on the inner side, and the winding wound later is located on the outer side, the number of coil turns of the winding located on the outer side is less than the number of coil turns of the winding located on the inner side.
[0006] In a preferred embodiment, the motor rotor winding method includes: S1, winding an N+M+a turns of coil to provide a first winding; S2, winding an N+M turns of coil to provide a second winding; S3, winding an N turns of coil to provide a third winding; S4, winding an NM turns of coil to provide a fourth winding; S5, winding an NMa turns of coil to provide a fifth winding, wherein N is an integer greater than 4, a is an integer not greater than 20% of N, and M is an integer less than (Na). In one preferred embodiment, M and a are both 1. In another preferred embodiment, M and a are both 2. In yet another preferred embodiment, M and a are both 3. It should be understood that the specific numbers listed herein are for illustrative purposes only and not as limitations.
[0007] In a preferred embodiment, the total number of turns in each slot is 2N. In one preferred embodiment, N is 39, and the total number of turns per slot is 78. In another preferred embodiment, N is 68, and the total number of turns per slot is 136. It should be understood that the specific figures listed herein are for illustrative purposes only and not as limitations.
[0008] In a preferred embodiment, the maximum deviation between the total number of output turns in each slot and the total number of designed turns accounts for less than 10% of the total number of designed turns.
[0009] In preferred embodiments, the maximum deviation between the total output turns in each slot and the designed total turns accounts for between 3% and 8% of the designed total turns. In one preferred embodiment, the maximum deviation between the total output turns in a single slot and the designed total turns is 3 turns, accounting for 3.8% of the designed total turns of 78 turns. In another preferred embodiment, the maximum deviation between the total output turns in a single slot and the designed total turns is 6 turns, accounting for 4.4% of the designed total turns of 136 turns. In yet another preferred embodiment, the maximum deviation between the total output turns in a single slot and the designed total turns is 4 turns, accounting for 5.1% of the designed total turns of 78 turns. In yet another preferred embodiment, the maximum deviation between the total output turns in a single slot and the designed total turns is 6 turns, accounting for 7.6% of the designed total turns of 78 turns. It should be understood that the specific figures listed herein are for illustrative purposes only and are not limitations.
[0010] In a preferred embodiment, the motor rotor winding method further includes step S0 before step S1, winding an N+M+a+b turns of coil to provide the zeroth winding, and step S6 after step S5, winding an NMab turns of coil to provide the sixth winding, wherein b is an integer not greater than 20% of N. In one preferred embodiment, b is 1. In another preferred embodiment, b is 2. It should be understood that the specific numbers listed herein are for illustrative purposes only and not as limitations.
[0011] In a preferred embodiment, the motor rotor winding method is single-flying fork or double-flying fork winding.
[0012] The motor rotor winding method according to the present invention is easier to wind and has a more optimized process; the same slot position can reduce the risk of wire ejection, and there is no need to increase the size of the slot, thus saving space; there is less imbalance, less motor heat loss, and improved performance. Attached Figure Description
[0013] Figure 1 The wire wrapping of a prior art motor rotor winding structure is shown.
[0014] Figure 2 This illustrates a prior art 4-pole 10-slot double-flying winding method.
[0015] Figure 3This is a motor rotor winding method according to Embodiment 1 of the present invention.
[0016] Figure 4 Show Figure 3 The winding process of the motor rotor winding method.
[0017] Figure 5 Showing according to Figure 3 The obtained motor rotor winding structure.
[0018] Figure 6 Show Figure 5 The coil of the motor rotor winding structure does not expand.
[0019] Figure 7 This illustrates a prior art 2-pole 7-slot single-fly winding method.
[0020] Figure 8 This is a motor rotor winding method according to Embodiment 2 of the present invention.
[0021] Figure 9 Show Figure 8 The winding process of the motor rotor winding method.
[0022] Figure 10 Showing according to Figure 8 The obtained motor rotor winding structure. Detailed Implementation
[0023] The preferred embodiments of the present invention are given below with reference to the accompanying drawings and described in detail.
[0024] The motor rotor winding method described in this paper is a single-layer lap winding. Each winding includes N upper coil sides and N lower coil sides. The N upper coil sides are located in one slot, and the N lower coil sides are located in another slot separated by at least one pitch. Specifically, the winding consists of N coils, each coil consisting of one upper coil side, one lower coil side, and two end sides. Therefore, a winding consists of N upper coil sides, N lower coil sides, and two N end sides. All upper coil sides of a winding are located in one slot, and all lower coil sides of a winding are located in another slot separated by at least one pitch.
[0025] Example 1
[0026] This embodiment involves a 4-pole, 10-slot rotor.
[0027] like Figure 2As shown, the existing motor rotor winding method includes: S1, the left and right fly forks wind 39 turns each to provide the first and sixth windings; S2, the left and right fly forks wind 39 turns each to provide the second and seventh windings; S3, the left and right fly forks wind 39 turns each to provide the third and ninth windings; S4, the left and right fly forks wind 39 turns each to provide the fourth and ninth windings; S5, the left and right fly forks wind 39 turns each to provide the fifth and tenth windings. Thus, after the rotor is wound to the last coil, the enamel wire accumulates severely at the slot opening, causing wire swelling, such as... Figure 1 As shown.
[0028] like Figure 3 and Figure 4 As shown, the motor rotor winding method according to this embodiment includes: S1, the left and right fly forks respectively wind N+M+a turns to provide the first and sixth windings; S2, the left and right fly forks respectively wind N+M turns to provide the second and seventh windings; S3, the left and right fly forks respectively wind N turns to provide the third and ninth windings; S4, the left and right fly forks respectively wind NM turns to provide the fourth and ninth windings; S5, the left and right fly forks respectively wind NMa turns to provide the fifth and tenth windings. Thus, through an unequal (more turns at the beginning and fewer at the end) winding design, while ensuring that the total number of turns in each slot meets the design requirements, the accumulation of enamel wire at the slot opening is reduced after the rotor is wound to the last coil, thus lowering the risk of wire breakage.
[0029] Specifically, the resulting motor rotor winding structure is as follows: Figure 5 As shown, the system includes ten slots 1-10 and ten windings AJ. The upper and lower coil sides of each winding AJ are located in two slots 1-10, and each slot 1-10 contains upper and lower coil sides belonging to two windings AJ. Specifically, the upper coil of the first winding A is located in slot 1, and the lower coil of the first winding A is located in slot 3; the upper coil of the second winding B is located in slot 2, and the lower coil of the second winding B is located in slot 4; the upper coil of the third winding C is located in slot 3, and the lower coil of the third winding C is located in slot 5; the upper coil of the fourth winding D is located in slot 4, and the lower coil of the fourth winding D is located in slot 6; the upper coil of the fifth winding E is located in slot 5, and the lower coil of the fifth winding E is located in slot 6. In 7, the upper coil of the sixth winding F is located in slot 6, the lower coil of the sixth winding F is located in slot 8, the upper coil of the seventh winding G is located in slot 7, the lower coil of the seventh winding G is located in slot 9, the upper coil of the eighth winding is located in slot 8, the lower coil of the eighth winding is located in slot 10, the upper coil of the ninth winding I is located in slot 9, the lower coil of the ninth winding I is located in slot 1, the upper coil of the tenth winding J is located in slot 10, and the lower coil of the tenth winding J is located in slot 2.
[0030] Specifically, the coils of the first winding A and the sixth winding F are N+M+a turns respectively, the coils of the second winding B and the seventh winding G are N+M turns respectively, the coils of the third winding C and the ninth winding H are N turns respectively, the coils of the fourth winding D and the ninth winding I are NM turns respectively, and the coils of the fifth winding E and the tenth winding J are NMa turns respectively, where N is an integer greater than 4, a is an integer not greater than 20% of N, and M is an integer less than (Na).
[0031] In this embodiment, N is 39, M is 2, and a is 2. For the specific winding distribution, please refer to Tables 1, 2, and 3 below:
[0032] Table 1
[0033] Table 2 Total number of output turns Total number of turns in design deviation Slot 1 80 78 2 Slot 2 76 78 -2 Slot 3 82 78 4 Slot 4 78 78 0 Slot 5 74 78 -4 Slot 6 80 78 2 Slot 7 76 78 -2 Slot 8 82 78 4 Slot 9 78 78 0 Slot 10 74 78 -4 Actual total number of turns 780 Total number of turns in design 780
[0034] Table 3 Number of turns at the top Number of turns at the bottom Total number of turns 43 37 80 41 35 76 39 43 82 37 41 78 35 39 74 43 37 80 41 35 76 39 43 82 37 41 78 35 39 74 390 390 780
[0035] Clearly, the total number of turns matches the designed number of turns, and the total number of turns on the upper and lower sides is the same. The maximum deviation between the total output turns per slot and the designed total number of turns is 4 turns, accounting for approximately 5.1% of the designed total of 78 turns, verifying that there are no performance or noise issues. Specifically, the motor performance and noise of the motor rotor winding mechanism in this embodiment are at the same level as those of the prior art (the difference is within 1%, including product consistency error).
[0036] As we know from the working principle of an electric motor, the electromagnetic forces generated by the upper and lower coil sides within the rotor slots due to their different energizing directions are in the same direction. Therefore, assuming the total number of turns within the same slot is equal, the number of turns on the upper and lower sides can be distributed with more turns at the top and less at the bottom without significantly affecting the motor's performance. This invention, through a clever arrangement of the rotor winding turns, fully utilizes the internal space of the slots and solves the problem of coil expansion in existing technologies. Figure 4 As shown, this reduces the risk of rotor wire slippage without affecting the original performance of the motor. Moreover, this winding method compensates for the resistance differences caused by the varying lengths of the ends of each coil, making the resistance value of each coil of the rotor more uniform and reducing the performance fluctuation of the motor. At the same time, because there is more copper wire on the inner side than on the outer side, the imbalance is closer to the shaft center, resulting in less imbalance.
[0037] In specific applications, the standard for room temperature flying wire testing includes: 24V power-on, CW 60s -> stop 60s -> CCW60, production line retest performance evaluation, 80 motors were tested at room temperature flying wire and their performance and noise were retested, and no abnormalities were found.
[0038] In specific applications, the high-temperature flying wire test standard is as follows: store at 85℃ for 2 hours, then power on at 24V, CW60s->stop for 60s->CCW60, and then retest the performance on the production line. After the high-temperature flying wire test was performed on 5 motors, the performance and noise were retested, and no abnormalities were found.
[0039] Example 2
[0040] This embodiment involves a 2-pole, 7-slot rotor.
[0041] like Figure 7 As shown, the existing motor rotor winding method includes: S1, winding 39 turns with a single fork to provide the first winding; S2, winding 39 turns with a single fork to provide the second winding; S3, winding 39 turns with a single fork to provide the third winding; S4, winding 39 turns with a single fork to provide the fourth winding; S5, winding 39 turns with a single fork to provide the fifth winding; S6, winding 39 turns with a single fork to provide the sixth winding; S7, winding 39 turns with a single fork to provide the seventh winding. Thus, after the rotor is wound to the last coil, the enamel wire accumulates severely at the slot opening, resulting in wire swelling.
[0042] like Figure 8 and Figure 9 As shown, the motor rotor winding method according to this embodiment includes: S1, a single fork winds N+M+a+b turns to provide a first winding; S2, a single fork winds N+M+a turns to provide a second winding; S3, a single fork winds N+M turns to provide a third winding; S4, a single fork winds N turns to provide a fourth winding; S5, a single fork winds NM turns to provide a fifth winding; S6, a single fork winds NMa turns to provide a sixth winding; S7, a single fork winds NMab turns to provide a seventh winding. Thus, through an uneven (more turns at the beginning, fewer at the end) winding design, while ensuring the total number of turns in each slot meets the design requirements, the accumulation of enamel wire at the slot opening is reduced after the rotor is wound to the last coil, thus lowering the risk of wire breakage.
[0043] like Figure 10As shown, the motor rotor winding structure according to this embodiment includes seven slots 1'-7' and seven windings A'-G', wherein the upper and lower coil sides of each winding A'-G' are located in two slots 1'-7', and each slot 1'-7' has upper and lower coil sides belonging to the two windings A'-G' respectively. Specifically, the upper coil of the first winding A' is located in slot 1', and the lower coil of the first winding A' is located in slot 4'; the upper coil of the second winding B' is located in slot 2', and the lower coil of the second winding B' is located in slot 5'; the upper coil of the third winding C' is located in slot 3', and the lower coil of the third winding C' is located in slot 6'; the upper coil of the fourth winding D' is located in slot 4', and the lower coil of the fourth winding D' is located in slot 7'; the upper coil of the fifth winding E' is located in slot 5', and the lower coil of the fifth winding E' is located in slot 1'; the upper coil of the sixth winding F' is located in slot 6', and the lower coil of the sixth winding F' is located in slot 2'; the upper coil of the seventh winding G' is located in slot 7', and the lower coil of the seventh winding G' is located in slot 3'.
[0044] Specifically, the first winding A' has N+M+a+b turns, the second winding B' has N+M+a turns, the third winding C' has N+M turns, the fourth winding ' has N turns, the fifth winding E' has NM turns, the sixth winding F' has NMa turns, and the seventh winding G' has NMab turns.
[0045] In this embodiment, N is 39, M is 2, a is 2, and b is 2. For the specific winding distribution, please refer to Tables 4 and 5 below:
[0046] Table 4 slot Number of turns slot Number of turns First winding A' 1 45 4 45 Second winding B' 2 43 5 43 Third winding C' 3 41 6 41 Fourth winding D' 4 39 7 39 Fifth winding E' 5 37 1 37 Sixth winding F' 6 35 2 35 Seventh winding G' 7 33 3 33
[0047] Table 5
[0048] Clearly, the total number of turns matches the designed number of turns. The maximum deviation between the total output turns per slot and the designed total number of turns is 6 turns, accounting for approximately 7.6% of the designed total of 78 turns, verifying that there are no performance or noise issues. Specifically, the motor performance and noise of the motor rotor winding mechanism in this embodiment are at the same level as those of the prior art (the difference is within 1%, including product consistency error).
[0049] In a variation of this embodiment, N is 39, M is 3, a is 3, and b is 3. For the specific winding distribution, please refer to Tables 6 and 7 below:
[0050] Table 6 slot Number of turns slot Number of turns First winding A' 1 48 4 48 Second winding B' 2 45 5 45 Third winding C' 3 42 6 42 Fourth winding D' 4 39 7 39 Fifth winding E' 5 36 1 36 Sixth winding F' 6 33 2 33 Seventh winding G' 7 30 3 30
[0051] Table 7
[0052] Clearly, the total number of turns is consistent with the design number of turns. The maximum deviation of the total number of turns in a single slot from the design requirement is 9 turns, accounting for about 11.5% of the total design number of 78 turns. This verifies that the motor performance of this modified motor rotor winding mechanism is reduced by about 3.9%, and the average noise level deteriorates by about 2 dB.
[0053] Example 3
[0054] This embodiment involves a 4-pole, 14-slot dual-flying configuration.
[0055] In this embodiment, N is 39, M is 1, a is 1, and b is 1. For the specific winding distribution, please refer to Tables 8 and 9 below:
[0056] Table 8 slot Number of turns slot Number of turns slot Number of turns slot Number of turns First winding and sixth winding 1 42 4 42 8 42 11 42 Second winding and seventh winding 2 41 5 41 9 41 12 41 Third winding and ninth winding 3 40 6 40 10 40 13 40 Fourth and Ninth Windings 4 39 7 39 11 39 14 39 Fifth winding and tenth winding 5 38 8 38 12 38 1 38 Sixth and eleventh windings 6 37 9 37 13 37 2 37 Seventh winding and twelfth winding 7 36 10 36 14 36 3 36
[0057] Table 9
[0058] Clearly, the total number of turns matches the designed number of turns. The maximum deviation between the total output turns per slot and the designed total number of turns is 3 turns, accounting for approximately 3.8% of the designed total of 78 turns, verifying that there are no performance or noise issues. Specifically, the motor performance and noise of the motor rotor winding mechanism in this embodiment are at the same level as those of the prior art (the difference is within 1%, including product consistency error).
[0059] Example 4
[0060] This embodiment involves a 2-pole, 5-slot single-fly configuration.
[0061] In this embodiment, N is 68, M is 3, and a is 3. For the specific winding distribution, please refer to Tables 10 and 11 below:
[0062] Table 10 slot Number of turns slot Number of turns First winding 1 73 3 74 Second winding 2 71 4 71 Third winding 3 68 5 68 Fourth winding 4 65 1 65 Fifth winding 5 62 2 62
[0063] Table 11
[0064] Clearly, the total number of turns matches the designed number of turns. The maximum deviation between the total output turns per slot and the designed total number of turns is 6 turns, accounting for approximately 4.4% of the designed total of 136 turns, verifying that there are no performance or noise issues. Specifically, the motor performance and noise of the motor rotor winding mechanism in this embodiment are at the same level as those of the prior art (the difference is within 1%, including product consistency error).
[0065] In a variant of this embodiment, N is 68, M is 6, and a is 6. For the specific winding distribution, please refer to Tables 12 and 13 below:
[0066] Table 12 slot Number of turns slot Number of turns First winding 1 80 3 80 Second winding 2 74 4 74 Third winding 3 68 5 68 Fourth winding 4 62 1 62 Fifth winding 5 56 2 56
[0067] Table 13 Total number of output turns Total number of turns in design deviation Slot 1 142 136 6 Slot 2 130 136 -6 Slot 3 148 136 12 Slot 4 136 136 0 Slot 5 124 136 -12 Actual total number of turns 680 Total number of turns in design 680
[0068] Clearly, the total number of turns is consistent with the design number of turns. The maximum deviation of the total number of turns per slot from the design requirement is 12 turns, accounting for about 8.8% of the total design number of 136 turns. This verifies that the motor performance of this modified motor rotor winding mechanism is reduced by about 2%, and the average noise level deteriorates by about 1 dB.
[0069] It should be understood that the above-mentioned 4-pole 10-slot or 14-slot rotor double-flying winding design and 2-pole 7-slot or 5-slot rotor single-flying winding design are only examples and not limitations. Other brushed motor rotors with different numbers of slots and poles can also be implemented accordingly.
[0070] In summary, the motor rotor winding structure of the present invention solves the problem of wire expansion by changing the number of turns in the winding slot, which has good manufacturing feasibility. The motor produced has no abnormalities in performance, noise and high temperature performance, and is suitable for various motors such as permanent magnet DC motors.
[0071] The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of the invention. Various variations can be made to the above embodiments of the present invention. That is, all simple and equivalent changes and modifications made based on the claims and description of this invention fall within the protection scope of the claims of this patent. All aspects not described in detail in this invention are conventional technical content.
Claims
1. A method of winding a rotor of an electric machine, characterized in that, The motor rotor winding method is single-layer lap winding, each winding includes N upper coil sides and N lower coil sides, the N upper coil sides are located in one slot position, the N lower coil sides are located in another slot position which is separated by at least one pitch, each slot position includes upper and lower coil sides which belong to two windings respectively; for each slot position, the winding which is wound first is located at the inner side, the winding which is wound later is located at the outer side, the number of coil turns of the winding located at the outer side is less than the number of coil turns of the winding located at the inner side.
2. The motor rotor winding method of claim 1, wherein, The motor rotor winding method includes: S1, winding N+M+a turns of coils to provide a first winding; S2, winding N+M turns of coils to provide a second winding; S3, winding N turns of coils to provide a third winding; S4, winding N-M turns of coils to provide a fourth winding; S5, winding N-M-a turns of coils to provide a fifth winding, wherein N is an integer greater than 4, a is an integer not greater than 20% of N, and M is an integer less than (N-a).
3. The motor rotor winding method of claim 2, wherein, The designed total number of turns in each slot position is 2N.
4. The method of winding a motor rotor of claim 3, wherein, The maximum deviation of the output total number of turns in each slot position from the designed total number of turns accounts for less than 10% of the designed total number of turns.
5. The method of winding a motor rotor of claim 4, wherein, The maximum deviation of the output total number of turns in each slot position from the designed total number of turns accounts for 3%-8% of the designed total number of turns.
6. The motor rotor winding method of claim 2, wherein, The motor rotor winding method further includes step S0 before step S1, winding N+M+a+b turns of coils to provide a zeroth winding, and further includes step S6 after step S5, winding N-M-a-b turns of coils to provide a sixth winding, wherein b is an integer not greater than 20% of N.
7. The motor rotor winding method of claim 1, wherein, The motor rotor winding method is single-fork winding or double-fork winding.