Method of manufacturing a hollow cup winding and hollow cup winding
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- DELTA ELECTRONICS INC(CN)
- Filing Date
- 2025-07-18
- Publication Date
- 2026-06-26
Smart Images
Figure CN122292799A_ABST
Abstract
Description
Technical Field
[0001] This application relates to a method for manufacturing a hollow cup winding and a hollow cup winding manufactured using this method. Background Technology
[0002] Coreless motors typically have multiple coils. To form a coreless winding, additional operations are required to arrange these coils and stack them on top of each other.
[0003] To simplify the assembly process of hollow cup windings, an improved method for manufacturing hollow cup windings is needed to increase manufacturing efficiency. Summary of the Invention
[0004] According to some embodiments of this application, a method for manufacturing a hollow cup winding is provided, using a jig for manufacturing, in which a conductor is wound around the jig. The jig includes a first sub-jaw and a second sub-jaw arranged coaxially with the first sub-jaw. The method includes the following steps: concentrically winding a first sub-coil and a second sub-coil along the first sub-jaw and the second sub-jaw, respectively. A first inner lead of the first sub-coil and a second inner lead of the second sub-coil are respectively pre-reserved on the contact side of the first sub-coil and the second sub-coil that contacts the jig. The first inner lead and the second inner lead are respectively used as a first lead and a second lead, forming a junction.
[0005] In some embodiments, the first sub-clamp and the second sub-clamp rotate synchronously along an axial direction.
[0006] In some embodiments, the first inner outgoing line and the second inner outgoing line are the same conductor.
[0007] In some embodiments, before winding begins, a first proximal end of the first inner wire is fixed at a first fixing point of the first sub-clamp, and a second proximal end of the second inner wire is fixed at a second fixing point of the second sub-clamp.
[0008] In some embodiments, when viewed along an axial direction of the clamp, the first fixing point overlaps with the second fixing point.
[0009] In some embodiments, the first sub-coil and the second sub-coil are connected together via a connecting segment.
[0010] Furthermore, according to some embodiments of this application, a hollow cup winding is provided, comprising at least one coil. Each coil has a first sub-coil and a second sub-coil. A first lead of the first sub-coil and a second lead of the second sub-coil both extend from the inside of the coil. The first lead of the first sub-coil and the second lead of the second sub-coil are the same conductor.
[0011] In some embodiments, the first sub-coil and the second sub-coil are connected together via a connecting segment.
[0012] In some embodiments, the connecting segment is located on the outside of the coil.
[0013] In some embodiments, the first lead has a first proximal end, and the second lead has a second proximal end. When viewed along an axial direction, the first proximal end and the second proximal end overlap. Attached Figure Description
[0014] When reading the accompanying drawings, the following detailed description provides the best understanding of all aspects of this application. It should be noted that, according to standard operating procedures in the industry, the various features are not necessarily drawn to scale. In fact, the dimensions of various features may be arbitrarily enlarged or reduced for clarity of illustration.
[0015] Figure 1 The diagram illustrates a wire surrounding a clamp according to some embodiments of this application.
[0016] Figure 2 Some embodiments according to this application are shown, Figure 1 The diagram shows the fixture unfolding around the axis of symmetry A1.
[0017] Figure 3 This diagram illustrates a coil unfolded about the axis of symmetry A2, according to some embodiments of this application.
[0018] Figure 4 The flowchart illustrates a process of forming a coil using a fixture according to some embodiments of this application.
[0019] Explanation of reference numerals in the attached figures
[0020] 100: Fixtures
[0021] 101: First side
[0022] 102: Second side
[0023] 103: Third side
[0024] 104: Fourth side
[0025] 105: Winding spool
[0026] 107: Contact side,
[0027] 108: Nodes
[0028] 109: Nodes
[0029] 110: First sub-clamp,
[0030] 111: First fixed point
[0031] 120: Second sub-clamp
[0032] 121: Second fixed point
[0033] 200: Coil
[0034] 201: Inner side
[0035] 202: Outer side
[0036] 210: First sub-coil
[0037] 211: First team to qualify from the inside.
[0038] 212: First lead wire
[0039] 213: First proximal end,
[0040] 220: Second sub-coil
[0041] 221: Second team to qualify.
[0042] 222: Second lead-out line
[0043] 223: Second proximal end,
[0044] 230: Connecting section
[0045] 250: Wire,
[0046] 301, 302, 303, 304, 305: Steps
[0047] A1: Axis of symmetry
[0048] A2: Axis of symmetry
[0049] R: Rotation direction
[0050] Z: Axial direction. Detailed Implementation
[0051] The following disclosure provides many different embodiments or examples, and describes specific examples of various components and arrangements to implement different features of this application. For example, if this specification describes a first feature formed "above" or "on top of" a second feature, it means that it may include embodiments in which the first feature and the second feature are in direct contact, or embodiments in which an additional feature is formed between the first feature and the second feature, so that the first feature and the second feature are not in direct contact.
[0052] Relative spatial terms, such as "below" or "above," may be used in the embodiments to facilitate the description of the relationship between components or features in the drawings and other components or features. In addition to the orientations shown in the drawings, these spatial terms are intended to encompass different orientations of the device in use or operation. The device may be turned to different orientations (rotated 90 degrees or other orientations), and the spatial terms used herein may be interpreted in the same manner.
[0053] This application provides a clamp for winding a conductor around the clamp to form a hollow cup winding. Compared to prior art, the coil winding formed according to this application can utilize a concentric winding method to simultaneously wind two sub-coils on the clamp, which has the advantages of reducing the number of parts and improving production efficiency. The technical features of the clamp and hollow cup winding according to this application will be described in detail below.
[0054] First, refer to Figure 1 and Figure 2 The construction of the fixture 100 according to this application is described. Figure 1 The diagram shows a wire 250 surrounding a clamp 100 according to some embodiments of this application. Figure 2 Some embodiments according to this application are shown, Figure 1 A schematic diagram of the fixture 100 unfolding around the axis of symmetry A1.
[0055] like Figure 1 and Figure 2 As shown, the clamp 100 includes a first sub-clamp 110 and a second sub-clamp 120. During the winding of the hollow cup winding, the first sub-clamp 110 and the second sub-clamp 120 rotate simultaneously along a winding shaft 105. Figure 1 and Figure 2 In the figure, the winding shaft 105 is located at the center of the first sub-clamp 110 and the second sub-clamp 120, and extends along the Z-axis direction. Therefore, in the following text, the Z-axis direction, which is the direction of extension of the winding shaft 105, is also referred to as the axial direction Z.
[0056] like Figure 1 and Figure 2 As shown, the first sub-clamp 110 and the second sub-clamp 120 are arranged coaxially, and the first sub-clamp 110 and the second sub-clamp 120 have the same shape. In other words, the winding shaft 105 of the first sub-clamp 110 overlaps with the winding shaft 105 of the second sub-clamp 120. Therefore, in Figure 1 When viewed along the axial direction Z, the first sub-clamp 110 and the second sub-clamp 120 completely overlap.
[0057] In addition, although Figure 1 and Figure 2The first sub-clamp 110 and the second sub-clamp 120 are shown as rhomboids, but their shapes are not limited to this. In other embodiments, the first sub-clamp 110 and the second sub-clamp 120 may also be circular, elliptical, rectangular, or other polygonal shapes. Furthermore, the hollow cup winding formed using the first sub-clamp 110 and the second sub-clamp 120 may have a shape corresponding to the clamps.
[0058] like Figure 1 and Figure 2 As shown, during winding, in order to control the tension of the wire 250, the wire 250 is connected to nodes 108 and 109 outside the clamp 100. The clamp 100 can be unfolded with the axis of symmetry A1 passing through node 109 as the center, revealing... Figure 2 The state shown.
[0059] like Figure 2 As shown, the first sub-clamp 110 and the second sub-clamp 120 may each have a node 108. In this embodiment, the wires wound on the first sub-clamp 110 and the second sub-clamp 120 are the same wire 250, so the first sub-clamp 110 and the second sub-clamp 120 can share the node 109.
[0060] In an embodiment according to this application, the conductor 250 is wound along the first sub-clamp 110 to form the first sub-coil 210. Figure 3 ), and the wire 250 is wound around the second sub-coil 220 along the second sub-clamp 120 ( Figure 3 As mentioned above, the winding shaft 105 of the first sub-clamp 110 overlaps with the winding shaft 105 of the second sub-clamp 120. Therefore, when the first sub-clamp 110 and the second sub-clamp 120 rotate synchronously in the rotation direction R, the first sub-clamp 110 and the second sub-clamp 120 concentrically wind the first sub-coil 210 and the second sub-coil 220.
[0061] like Figure 2 As shown, the first sub-coil 210 formed using the first sub-clamp 110 (e.g.) Figure 3 As shown, it may have a first inner lead 211, and the second sub-coil 220 formed by the second sub-clamp 120 may have a second inner lead 221. Before the hollow cup winding begins, the first inner lead 211 and the second inner lead 221 are respectively reserved on the contact side that contacts the first sub-clamp 110 and the second sub-clamp 120.
[0062] exist Figure 1In the diagram, the portion of the clamp 100 that contacts the wire 250 is designated as the contact side 107. The contact side 107 is the portion that the wire 250 first touches when it travels around the clamp 100. For ease of explanation, the contact side 107 of the clamp 100 is further divided into a first side 101, a second side 102, a third side 103, and a fourth side 104, representing the four sides of the clamp 100, which is shown as a rhombus.
[0063] After reserving the first inner outgoing line 211 and the second inner outgoing line 221, respectively, the first proximal end 213 of the first inner outgoing line 211 ( Figure 3 ) Fixed at the first fixing point 111 of the first sub-clamp 110 ( Figure 2 ), and the second proximal end 223 of the second inner outgoing line 221 ( Figure 3 ) Fixed at the second fixing point 121 of the second sub-clamp 120 Figure 2 ).
[0064] exist Figure 2 In the illustrated embodiment, the first fixing point 111 of the first sub-clamp 110 is located at the corner of the first sub-clamp 110 closest to node 108, and the second fixing point 121 of the second sub-clamp 120 is also located at the corner of the second sub-clamp 120 closest to node 108. Viewed along the axial direction Z of the clamp 100, the first fixing point 111 of the first sub-clamp 110 and the second fixing point 121 of the second sub-clamp 120 overlap. However, the positions of the first fixing point 111 and the second fixing point 121 are not limited to... Figure 2 The location shown can be determined according to actual needs.
[0065] After the fixing is completed, the first sub-clamp 110 and the second sub-clamp 120 rotate synchronously along the rotation direction R, so that the two ends of the wire 250 are sequentially wrapped around the first sub-clamp 110 and the second sub-clamp 120 from the first side 101, the second side 102, the third side 103, and the fourth side 104, completing one round of winding.
[0066] By repeatedly rotating the clamp 100, the required number of turns of wire are formed, becoming the first sub-coil 210 and the second sub-coil 220. Since the first sub-coil 210 and the second sub-coil 220 are wound from the same wire 250, the first sub-coil 210 and the second sub-coil 220 are collectively referred to as coil 200.
[0067] Next, refer to Figure 3 The construction of the coil 200 according to this application is described. Figure 3The accompanying drawings show a schematic diagram of coil 200 unfolded about a symmetry axis A2 according to some embodiments of this application. The symmetry axis A2 is a virtual axis passing through the junction of the first sub-coil 210 and the second sub-coil 220. In reality, the coil 200 wound using the fixture 100 according to this application is not in an unfolded state; viewed along the axial direction Z, the first sub-coil 210 and the second sub-coil 220 have the same shape and completely overlap each other. For ease of explanation, the accompanying drawings present the first sub-coil 210 and the second sub-coil 220 of coil 200 in an unfolded state.
[0068] exist Figure 3 In the diagram, several arrows are used to represent wires 250. The arrows do not represent the order or direction of winding, but are used to conveniently indicate that the first sub-coil 210 and the second sub-coil 220 are formed using the same wire 250.
[0069] In some embodiments, the conductor 250 may be, for example, an enameled wire with self-adhesive properties. For instance, solvents such as alcohol can be used to fix multiple turns of conductor 250 together, or hot air can be used to fix the conductor 250. In this way, the coil 200 itself can be well fixed, improving stability.
[0070] According to an embodiment of this application, a hollow cup winding may include at least one coil 200. Each coil 200 has a first sub-coil 210 and a second sub-coil 220.
[0071] like Figure 3 As shown, the coil 200 can be divided into an inner side 201 and an outer side 202. The inner side 201 is the side closest to and in contact with the clamp 100, while the outer side 202 is the side furthest from the clamp 100. That is, the inner side 201 of the coil 200 corresponds to the contact side 107 of the clamp 100.
[0072] The first sub-coil 210 has a first lead 212 (i.e., Figure 2 The first inner lead 211), and the second sub-coil 220 has a second lead 222 (i.e., Figure 2 The first lead 212 and the second lead 222 both extend from the inner side 201 of the coil 200. Therefore, the first lead 212 and the second lead 222 are also referred to as the first inner lead 211 and the second inner lead 221.
[0073] In some embodiments, the first lead 212 and the second lead 222 may form a junction (not shown). This junction may be soldered, for example, to a printed circuit board or other similar component, and then electrically connected to a power supply device.
[0074] exist Figure 3In the illustrated embodiment, with Figure 2 Unlike the embodiment shown, the first lead 212 and the second lead 222 are not fixed at the corner closest to the node, but rather at a corner closer to the +Y direction in the attached figure. Specifically, the first lead 212 has a first proximal end 213, and the second lead 222 has a second proximal end 223. Before winding begins, the first proximal end 213 can be fixed at a first fixing point 111 of the first sub-clamp 110, and the second proximal end 223 can be fixed at a second fixing point 121 of the second sub-clamp 120.
[0075] As mentioned above, when viewed along the axial direction Z, the first fixing point 111 of the first sub-clamp 110 overlaps with the second fixing point 121 of the second sub-clamp 120. Therefore, the first proximal end 213 of the first sub-coil 210 also overlaps with the second proximal end 223 of the second sub-coil 220.
[0076] Furthermore, in embodiments according to this application, the first sub-coil 210 and the second sub-coil 220 are connected together via a connecting segment 230. For example... Figure 3 As shown, the connecting segment 230 is located between the first sub-coil 210 and the second sub-coil 220, and is situated on the outer side 202 of the coil 200. In some embodiments, the connecting segment 230 may be additionally fixed to other components (not shown) to enhance the stability of the coil 200. The length of the connecting segment 230 may be determined according to actual needs and is not limited to... Figure 3 The example shown.
[0077] Next, refer to Figure 4 This describes the method of forming coil 200 using clamp 100. Figure 4 The flowchart illustrates a process of forming a coil 200 using a clamp 100 according to some embodiments of this application.
[0078] In step 301, before starting the winding, the length of the conductor 250 required to wind a set of coils 200 is calculated. Since coil 200 includes a first sub-coil 210 and a second sub-coil 220, and the first sub-coil 210 and the second sub-coil 220 are formed by the same conductor 250, the required length of conductor 250 should be the sum of the length of the first sub-coil 210, the length of the second sub-coil 220, and the length of the connecting segment 230. Furthermore, in this embodiment, the length of the first sub-coil 210 includes the length of the reserved first inner lead 211 (i.e., the first lead 212), and the length of the second sub-coil 220 includes the length of the reserved second inner lead 221 (i.e., the second lead 222).
[0079] In step 302, after calculating the length of the wire 250, the fixed-length wire 250 is placed on the clamp 100. The two ends of the wire 250 (i.e., the first proximal end 213 and the second proximal end 223 mentioned above) are fixed to the first sub-clamp 110 and the second sub-clamp 120 respectively, and the wire 250 connects to nodes 108 and 109, as shown below. Figure 1 and Figure 2 As shown.
[0080] In step 303, after the conductor 250 is fixed, the tension of the conductor 250 is controlled by nodes 108 and 109, and the clamp 100 is rotated along the axial direction Z in the rotational direction R to perform winding.
[0081] Although two nodes (node 108 and node 109) are shown in the accompanying drawings of this application, the number of nodes is not limited thereto. The clamp 100 may correspond to any number of nodes as long as it is suitable for controlling the tension of the conductor 250.
[0082] In step 304, since the first sub-clamp 110 and the second sub-clamp 120 rotate synchronously and coaxially, both ends of the wire 250 are wound simultaneously, causing the wire 250 to sequentially wrap around the clamp 100 from the first side 101, the second side 102, the third side 103, and the fourth side 104 (see...). Figure 1 ), completing one loop of winding.
[0083] Next, repeat steps 303 and 304 according to the required number of coil turns to form the required coil 200.
[0084] In step 305, after several turns of winding, a coil 200 comprising a first sub-coil 210 and a second sub-coil 220 is completed, wherein the first sub-coil 210 and the second sub-coil 220 are connected by a connecting segment 230. Thus, the coil 200 according to this application is completed.
[0085] In the case where the hollow cup winding includes multiple coils 200, multiple coils 200 can be combined as needed to complete the hollow cup winding according to this application.
[0086] In summary, using the fixture 100 provided according to this application, the same wire 250 can be concentrically wound into a coil 200 including a first sub-coil 210 and a second sub-coil 220, thereby forming a hollow cup winding suitable for a coreless motor. The hollow cup winding according to this application has the advantages of reducing the number of coil parts and improving manufacturing efficiency.
[0087] While the embodiments and advantages of this application have been disclosed above, it should be understood that any person skilled in the art can make modifications, substitutions, and refinements without departing from the spirit and scope of this application. Furthermore, the scope of protection of this application is not limited to the processes, machines, manufacturing methods, material compositions, apparatuses, methods, and steps described in the specific embodiments of the specification. Any person skilled in the art can understand from the disclosure of this application any existing or future developed processes, machines, manufacturing methods, material compositions, apparatuses, methods, and steps that can perform substantially the same function or obtain substantially the same results in the embodiments described herein, and can be used according to this application. Therefore, the scope of protection of this application includes the aforementioned processes, machines, manufacturing methods, material compositions, apparatuses, methods, and steps. In addition, each claim constitutes an individual embodiment, and the scope of protection of this application also includes combinations of various claim claims and embodiments.
Claims
1. A method for manufacturing a hollow cup winding, characterized in that, The hollow cup winding is manufactured using a clamp, the clamp being used to wrap a wire around the clamp, the clamp comprising: A first sub-clamp; and A second sub-clamp is arranged coaxially with the first sub-clamp; The method includes the following steps: concentrically winding a first sub-coil and a second sub-coil along the first sub-clamp and the second sub-clamp respectively; A first inner lead of the first sub-coil and a second inner lead of the second sub-coil are respectively pre-reserved on the contact side of the first sub-coil and the second sub-coil where they contact the fixture; and The first inner outgoing line and the second inner outgoing line are respectively used as the first lead-out line and the second lead-out line, and a connection line is formed.
2. The method according to claim 1, characterized in that, The first sub-clamp and the second sub-clamp rotate synchronously along an axial direction.
3. The method according to claim 1, characterized in that, The first internal outgoing line and the second internal outgoing line are the same conductor.
4. The method according to claim 3, characterized in that, Before starting the winding, a first proximal end of the first inner wire is fixed at a first fixed point of the first sub-clamp, and a second proximal end of the second inner wire is fixed at a second fixed point of the second sub-clamp.
5. The method according to claim 4, characterized in that, Viewed along one axial direction of the clamp, the first fixing point overlaps with the second fixing point.
6. The method according to claim 1, characterized in that, The first sub-coil and the second sub-coil are connected together via a connecting segment.
7. A hollow cup winding, characterized in that, include: At least one coil, each coil having: A first sub-coil; and The second sub-coil; The first lead of the first sub-coil and the second lead of the second sub-coil are both led out from the inside of the coil; The first lead of the first sub-coil and the second lead of the second sub-coil are the same wire.
8. The hollow cup winding according to claim 7, characterized in that, The first sub-coil and the second sub-coil are connected together via a connecting segment.
9. The hollow cup winding according to claim 8, characterized in that, The connection segment is located on the outside of the coil.
10. The hollow cup winding according to claim 7, characterized in that, The first lead has a first proximal end, and the second lead has a second proximal end, wherein the first proximal end overlaps with the second proximal end when viewed along an axial direction.