U-shaped coreless linear motor winding structure and motor

Abstract

The invention discloses a U-shaped coreless linear motor winding structure and a motor, and relates to the field of linear motors. The invention aims to solve the problems that a winding of an existing U-shaped coreless motor is complex to manufacture, single coil structures are different, and end structures are in cross contact, so that the operation reliability and the service life of the motor are seriously threatened. The motor winding structure comprises at least one unit winding, the end part of each coil in the unit winding is U-shaped, two end parts and two linear parts are alternately arranged and connected end to end to form a ring, and the two end parts are bent towards the same side of the two linear parts; the coils are sequentially arranged in the moving direction of the linear motor, the two groups of coils are arranged oppositely, so that the end parts of the two groups of coils face opposite directions, the end parts of the adjacent coils are not in contact with each other, and the linear parts of the two adjacent coils in one group of coils are embedded into the U-shaped groove of one coil in the other coil group at the same time; and when the number of the unit windings is greater than 1, the linear parts and the vacancies of two adjacent unit windings are mutually embedded.

Description

Technical Field

[0001] This application belongs to the field of linear motors, and in particular relates to motor winding structures. Background Technology

[0002] U-shaped coreless permanent magnet linear motors are used in applications requiring high precision due to the absence of cogging effect, small thrust fluctuation, and high positioning accuracy. However, because they lack a core, they cannot provide a magnetic circuit, resulting in lower output thrust compared to motors with cores. Under existing winding structures, motor windings can employ distributed windings or concentrated windings. When using concentrated windings, a single-layer structure is typically used. The advantage of this structure is that the coil windings do not cross, and the spatial arrangement is simple. However, the two sides of the same coil can only be distributed with a 120-degree electrical angle difference, leading to low winding utilization and reduced motor output thrust. To improve the output thrust of coreless motors, a distributed winding structure can be used to increase the utilization rate of the winding coil sides. This winding structure requires the ends of the coil windings to cross spatially; it is relatively complex to manufacture and places higher demands on the motor's insulation.

[0003] The winding structures described in the patent documents with publication numbers CN113270958B and CN217282646U both adopt a distributed structure. In order to allow the ends to be installed and arranged, a double-layer winding structure is adopted. The ends of the coils are staggered by means of staggered arrangement and different bending angles, and then the two single-layer windings are combined together.

[0004] Currently, the winding manufacturing method for U-shaped coreless motors is basically the same as described above, requiring a mold to extrude and shape the coil into a specific form. This method only complicates winding manufacturing, resulting in different structures for individual coils; furthermore, the end structures are in cross-contact, posing a significant risk of phase-to-phase insulation breakdown, especially under high temperature or high voltage conditions. Weak points in the insulation are prone to partial discharge, accelerating insulation aging and leading to phase-to-phase or turn-to-turn short circuits, seriously threatening the motor's operational reliability and lifespan. Summary of the Invention

[0005] This application aims to address the problem that existing U-shaped coreless motors have complex windings, inconsistent individual coil structures, and overlapping end contacts, which seriously threaten the reliability and lifespan of the motor. The application provides a U-shaped coreless linear motor winding structure and the motor itself.

[0006] The first aspect of this application provides a U-shaped coreless linear motor winding structure.

[0007] It includes at least one unit winding, and each unit winding includes N coils, where N is a positive integer greater than or equal to 3;

[0008] Each coil includes two ends and two straight sections. The ends are U-shaped. The two ends and the two straight sections are arranged alternately and connected end to end to form a loop. Both ends are bent toward the same side of the two straight sections.

[0009] When N is odd, the coils in the unit winding are divided into two coil groups with a difference of 1 in number; when N is even, the coils in the unit winding are divided into two coil groups with an equal number of coils.

[0010] Each group of coils is arranged sequentially along the direction of motion of the linear motor, and the two groups of coils are set back to back, so that the ends of the two groups of coils face opposite directions and the ends of adjacent coils do not touch each other. The straight parts of two adjacent coils in one group of coils are simultaneously embedded into the U-shaped groove of one coil in another group of coils, so that each of the two coils at the ends has an empty space in the U-shaped groove.

[0011] When the number of unit windings is greater than 1, all unit windings are arranged sequentially along the direction of motion of the linear motor, and the straight sections of two adjacent unit windings are interlocked with the empty spaces.

[0012] In one possible design, both ends of the coil are bent at 90° toward the same side of the two straight sections.

[0013] In one possible design, the electrical angle between the two effective sides of the coil is 180°.

[0014] In one possible design, the unit winding includes three coils.

[0015] In one possible design, the three coils are phase A, phase C, and phase B, and each is a single-layer coil.

[0016] The second aspect of this application provides a motor containing the above-mentioned U-shaped coreless linear motor winding structure, including a winding structure and a secondary component, wherein the winding structure is embedded inside the secondary component to form a linear motor.

[0017] The beneficial effects of this application are:

[0018] The motor winding structure described in this application has an electrical angle of 180° between the two effective sides of a coil, and the ends of the coils cross each other in space without contacting each other, which satisfies the arrangement of distributed windings, improves the utilization rate of windings, and thus the motor can output higher force. Attached Figure Description

[0019] Figure 1 This is a three-dimensional structural diagram of the stator coil module of a linear motor;

[0020] Figure 2The diagram shows the planar structure of the stator coil module of a linear motor, including (a) a side view, (b) a front view, and (c) an end view.

[0021] Figure 3 This is a schematic diagram of a single-unit winding structure;

[0022] Figure 4 The diagram shows a plan view of the unit winding structure: (a) front view, (b) side view, and (c) end view.

[0023] Figure 5 A schematic diagram showing the direction of current flow in the plane of a single-unit winding structure;

[0024] Figure 6 A schematic diagram of the connection and installation of a multi-unit winding structure;

[0025] Figure 7 This is an overall view of the winding structure and secondary engagement state.

[0026] Figure 8 This is a side view of the winding structure and its engagement with the secondary winding.

[0027] In the diagram, 10 represents the coil, 101 represents the end of the coil, 102 represents the straight section of the coil, 11 represents the unit winding, 12 represents the winding structure, and 13 represents the secondary component. Detailed Implementation

[0028] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application. It should be noted that, unless otherwise specified, the embodiments and features in the embodiments of this application can be combined with each other.

[0029] Specific implementation method one: as follows Figures 1 to 6 As shown, the U-shaped coreless linear motor winding structure described in this embodiment...

[0030] It includes at least one unit winding, and each unit winding includes N coils, where N is a positive integer greater than or equal to 3;

[0031] Each coil includes two ends and two straight sections. The ends are U-shaped. The two ends and the two straight sections are arranged alternately and connected end to end to form a loop. Both ends are bent toward the same side of the two straight sections.

[0032] When N is odd, the coils in the unit winding are divided into two coil groups with a difference of 1 in number; when N is even, the coils in the unit winding are divided into two coil groups with an equal number of coils.

[0033] Each group of coils is arranged sequentially along the direction of motion of the linear motor, and the two groups of coils are set back to back, so that the ends of the two groups of coils face opposite directions and the ends of adjacent coils do not touch each other. The straight parts of two adjacent coils in one group of coils are simultaneously embedded into the U-shaped groove of one coil in another group of coils, so that each of the two coils at the ends has an empty space in the U-shaped groove.

[0034] When the number of unit windings is greater than 1, all unit windings are arranged sequentially along the direction of motion of the linear motor, and the straight sections of two adjacent unit windings are interlocked with the empty spaces.

[0035] In one embodiment, the coil has both ends bent at 90° toward the same side of the two straight sections.

[0036] In one embodiment, the electrical angle between the two effective sides of the coil is 180°.

[0037] In one embodiment, the unit winding includes three coils.

[0038] In one embodiment, the three coils are phase A coil, phase C coil, and phase B coil, and each is a single-layer coil.

[0039] Specific implementation method two: such as Figure 7 and Figure 8 As shown, the motor in this embodiment, which contains the U-shaped coreless linear motor winding structure described in Specific Embodiment 1, includes a winding structure and a secondary component. The winding structure is embedded inside the secondary component to form a linear motor.

[0040] To further describe the two embodiments of this application, a detailed explanation is provided below:

[0041] like Figure 6 As shown, this embodiment provides a U-shaped coreless modular multi-unit winding structure, including at least one unit winding 11; the unit winding includes at least 3 coils 10.

[0042] In order to achieve such Figure 3 The arrangement of the middle unit winding 11 and the structural design and fabrication of the coil 10 are as follows: Figure 1 and Figure 2The coil 10, as shown, comprises a straight portion 102 and coil ends 101 located at both ends of the straight portion 102, forming a closed loop. The coil ends 101 are bent 90 degrees toward the same side of the straight portion 102. The required bending length is calculated and measured, and the middle of the bent end is hollowed out, leaving space for other coils to be arranged. Then, three coils 10 are installed in a positive-negative-positive arrangement, ensuring that the straight portion 102 of a single coil satisfies a 180° electrical angle in the electromagnetic field. The overlapping portions of the coil ends 101 are staggered vertically, and the coil ends 101 of adjacent coils 10 do not contact each other.

[0043] like Figure 3 As shown, the two ends of a single unit winding 11 leave empty spaces for the two coil straight sections 102, resulting in low space utilization for a single unit winding 11 compared to conventional methods. However, when multiple units are used, such as Figure 6 As shown, the empty space after the first unit winding 11 is filled by the coil straight section 102 in front of the second single winding 11, and the empty space in front of the coil straight section 102 of the second unit winding 11 is filled by the first unit winding 11. Through this splicing method, no matter how many unit motors are spliced, only the first unit winding 11 and the last unit winding 11 will have empty spaces, thus solving the problem of insufficient space utilization.

[0044] like Figure 7 and Figure 8 As shown, the winding structure 12 is installed inside the secondary component 13 (it needs to be connected through other functional components, which will not be described here), forming a linear motor. The secondary component 13 provides a magnetic field, and after three-phase current is passed through the winding, it couples with the secondary magnetic field to generate electromagnetic thrust.

[0045] This embodiment provides a single coil structure in its first aspect, which has the advantage of avoiding contact between coils while allowing the ends to cross. The second aspect provides a coil arrangement for a three-phase winding, enabling the coils to fulfill the functional structure of a distributed winding after connection. The third aspect provides a unit-structured winding, where a single or multiple winding units can be set; when multiple units are set, only individual units need to be arranged sequentially along the direction of movement. The fourth aspect involves the effective sides of the three coils in the three-phase winding unit arranged in the following order: A-phase positive, C-phase positive, A-phase negative, B-phase positive, C-phase negative, B-phase negative. The fifth aspect involves all three phases (A-phase, B-phase, and C-phase) being single-layer coils.

[0046] While specific embodiments of this application have been described herein with reference to them, it should be understood that these embodiments are merely examples of the principles and applications of this application. Therefore, it should be understood that many modifications can be made to the exemplary embodiments, and other arrangements can be designed without departing from the spirit and scope of this application as defined by the appended claims. It should be understood that different dependent claims and features described herein can be combined in ways different from those described in the original claims. It is also understood that features described in conjunction with individual embodiments can be used in other described embodiments.

Claims

1. A U-shaped coreless linear motor winding structure, characterized in that, It includes at least one unit winding, and each unit winding includes N coils, where N is a positive integer greater than or equal to 3; Each coil includes two ends and two straight sections. The ends are U-shaped. The two ends and the two straight sections are arranged alternately and connected end to end to form a loop. Both ends are bent toward the same side of the two straight sections. When N is odd, the coils in the unit winding are divided into two coil groups with a difference of 1 in number; when N is even, the coils in the unit winding are divided into two coil groups with an equal number of coils. Each group of coils is arranged sequentially along the direction of motion of the linear motor, and the two groups of coils are set back to back, so that the ends of the two groups of coils face opposite directions and the ends of adjacent coils do not touch each other. The straight parts of two adjacent coils in one group of coils are simultaneously embedded into the U-shaped groove of one coil in another group of coils, so that each of the two coils at the ends has an empty space in the U-shaped groove. When the number of unit windings is greater than 1, all unit windings are arranged sequentially along the direction of motion of the linear motor, and the straight sections of two adjacent unit windings are interlocked with the empty spaces.

2. The U-shaped coreless linear motor winding structure according to claim 1, characterized in that, In the coil, both ends are bent at 90° toward the same side of the two straight sections.

3. The U-shaped coreless linear motor winding structure according to claim 1, characterized in that, The electrical angle between the two effective sides of the coil is 180°.

4. The U-shaped coreless linear motor winding structure according to claim 1, characterized in that, The unit winding includes three coils.

5. The U-shaped coreless linear motor winding structure according to claim 4, characterized in that, The three coils are phase A, phase C, and phase B, and each is a single-layer coil.

6. A motor comprising the U-shaped coreless linear motor winding structure according to any one of claims 1 to 5, characterized in that, It includes a winding structure and a secondary component, wherein the winding structure is embedded inside the secondary component to form a linear motor.

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