Disc-shaped armature for disc-type motor and packaging device
By using unsaturated polyester plastic sheets containing short glass fibers for thermo-press curing and encapsulation on both sides of the coil winding of the disc armature, the structural stability problem of the disc armature under high temperature and high intensity environment is solved, higher structural strength and electrical performance are achieved, and the degree of automation of encapsulation is improved.
Patent Information
- Application Number
- CN202422785462.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-11-15
- Publication Date
- 2025-10-28
- Estimated Expiration
- 2034-11-15
AI Technical Summary
Existing disc armatures are difficult to maintain structural strength and stability under high heat and high speed rotation environments. Self-adhesive materials are prone to softening or melting at high temperatures, leading to winding deformation or displacement.
The curing and encapsulation process is adopted. Unsaturated polyester plastic sheets containing short glass fibers are placed on both sides of the disc coil winding. The sheets are then hot-pressed and cured using an automatic pressure forming machine to form a tightly connected curing and encapsulation, thus avoiding irregular flow and deformation.
It improves the structural strength and electrical performance of the armature, adapts to high temperature and high intensity environments, ensures packaging quality and consistency, and enhances the automation level of the packaging process.
Smart Images
Figure CN223488043U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the technical field of DC motors, and in particular to a disc armature and packaging device for a disc motor. Background Technology
[0002] In certain specific applications, such as in flat, confined spaces, a coreless DC motor with a rotor without an iron core is often used. As an axial flux motor, it is characterized by its small size, flat shape, high power density, high efficiency, low rotor inertia, low iron loss, and low stall torque. With the development of new supporting technologies and the application of high-performance magnetic materials, its application range is becoming increasingly wide, including in applications such as electric wheel hubs, fans, and industrial robots.
[0003] The motor stator consists of multiple sector-shaped permanent magnet plates arranged in a ring and a magnetic yoke plate fixed to the housing. The motor rotor is a coreless disc-shaped armature. The disc-shaped armature is composed of multiple sector-shaped coils evenly distributed in a ring around the radial horizontal plane of the commutator. These coils are sequentially connected in series and welded to corresponding mutually insulated commutator copper plates on the outer cylindrical surface of the commutator. The motor shaft is fastened within the central shaft hole of the commutator and is connected to the motor housing via a bearing. The disc-shaped armature is positioned within the axially flat space between the magnet plane and the yoke plane of the stator structure. When the motor is energized, the energized coils rotate under the influence of the magnetic field, causing the commutator to change magnetic poles, thereby continuously changing the direction of the current. Each energized coil sequentially cuts the magnetic lines of force, thus generating a continuous torque.
[0004] In practical applications, although individual sector coils and the entire armature coil can be precisely positioned, pressured, and energized to heat-set using the self-adhesive properties of self-adhesive enameled wire, seemingly forming a decent rotor disc, these self-adhesive materials are all thermoplastic materials. The disc-shaped armature windings shaped in the above way are difficult to withstand the working environment of high heat, high strength, and high speed rotation. Utility Model Content
[0005] To improve the structural strength and operational stability of the armature, this application provides a disc-shaped armature for a disc motor and a packaging device thereon.
[0006] The technical solution provided in this application for a disc-shaped armature and encapsulation device for a disc motor adopts the following:
[0007] A disc-shaped armature for a disc motor includes a commutator. A disc-shaped coil winding is welded and fixed to the outside of the commutator. The disc-shaped coil winding is composed of multiple sector coils connected in series and wound around each other. Any sector coil is wound with enameled wire. Any adjacent enameled wires are self-adhesive and fixed after being heated and pressed. A plastic-molded curing encapsulation is provided on the outside of the disc-shaped coil winding.
[0008] By adopting the above technical solution, and by welding and fixing the fan-shaped disc coil windings to the outside of the commutator and then self-adhesive fixing them, a tight connection between the coils is ensured, improving the overall structural strength and electrical performance of the armature. At the same time, the use of a hot-press curing molding process instead of an injection molding process ensures the robustness and rigidity of the disc armature, enabling it to adapt to high-temperature and high-intensity working environments. The encapsulated package after hot pressing curing is less likely to soften or melt at high temperatures.
[0009] Preferably, the curing encapsulation includes two pre-pressed sheets formed by cold pressing. The two pre-pressed sheets are respectively disposed on both sides of the disc coil winding along the commutator axis. Both pre-pressed sheets are made of unsaturated polyester plastic sheets containing short glass fibers. The two pre-pressed sheets are hot-pressed and cured on the disc coil winding and the upper end of the commutator by an automatic pressure forming machine.
[0010] By adopting the above technical solution, instead of the direct feeding method used in traditional pressure bonding processes, a pre-prepared cold-pressed pre-compressed sheet is placed on both sides of the disc coil winding. During the heating and pressing process, the molten unsaturated polyester plastic flows and fills the molding cavity of the encapsulation device, thus tightly wrapping and solidifying the entire disc coil winding and the upper part of the commutator. This method avoids irregular flow of the unsaturated polyester plastic during the pressing process, which could cause deformation or displacement of the winding coil, thereby ensuring the encapsulation effect. Short glass fibers help to further increase the structural strength of the encapsulation, and are used to ensure the fluidity of the molten unsaturated polyester plastic during pressing.
[0011] Preferably, the solidified encapsulation includes an outer edge protrusion for balancing and a boss for accommodating the interconnecting wires of the commutator upper end and the sector coil.
[0012] By adopting the above technical solution, the outer edge protrusion not only improves the strength of the packaging edge structure, but also makes it easier for staff to find the unbalanced position when checking the dynamic balance of the disc armature on the balancing machine, and remove the weight at the corresponding outer edge protrusion, thereby avoiding damage to the disc coil winding and connecting wires.
[0013] An encapsulation device includes an upper heating plate and a lower heating plate fixed on an automatic pressure forming machine. A die is fixed on the upper side of the lower heating plate. A disc-shaped coil winding and two pre-pressing plates disposed on both sides thereon are placed inside the die. A lower insert is detachably fixed to the bottom of the die. The pre-pressing plates on the lower side are disposed on the upper side of the lower insert. A central hole is also provided on the lower insert. The lower end of the commutator slides and engages with the central hole in a vertical direction. The lower end of the commutator is embedded in the central hole. A punch is fixed on the lower side of the upper heating plate. When the punch and the die are closed, the lower end of the punch is embedded in the die.
[0014] By adopting the above technical solution, the operator first places the lower pre-pressed sheet on the lower insert. The lower pre-pressed sheet has through holes formed on it. A commutator with a disc-shaped coil winding, welded to it, is placed on the lower pre-pressed sheet. The lower end of the commutator passes through the through hole and slides into the center hole on the lower insert, fitting within it. The operator then places the upper pre-pressed sheet on top of the commutator. After the automatic pressure forming machine drives the encapsulation device to close the mold, the upper and lower heating plates on the automatic pressure forming machine simultaneously heat the punch and die, causing the pre-pressed sheet to melt and gradually fill the forming cavity of the device under pressure, achieving rapid hot-pressing solidification. The die helps to position the disc-shaped coil winding, ensuring that it remains relatively fixed within the die during hot-pressing, thus guaranteeing the hot-pressing effect. The detachable lower insert allows for changes in the area and shape of the boss, making the encapsulation device suitable for different models and structures of disc-shaped coil windings.
[0015] Preferably, a lower template is fixed on the upper side of the lower heating plate, and a core is fixed on the lower template. The core is coaxially arranged with the commutator, and the upper end of the core passes through the punch in the vertical direction. The lower insert is detachably fixed on the lower template.
[0016] By adopting the above technical solution, when the disc armature is placed in the die, the core helps to position the disc armature and ensure the relative position of the disc armature in the die.
[0017] Preferably, the lower heating plate is provided with a push rod driven by an automatic pressure forming machine. The push rod passes through the lower heating plate in a vertical direction. A top ring is fixed at the upper end of the push rod. The top ring slides in the cavity along the core axis. The lower insert is embedded in the top ring. The top ring is coaxial with the core.
[0018] By adopting the above technical solution, after hot pressing, the automatic pressure forming machine moves the lower heating plate downwards, thereby separating the punch and die. The automatic pressure forming machine drives the ejector rod to push the top ring, separating the formed, cured package from the die, making it easier for workers to remove the packaged disc armature. The top ring helps ensure a larger contact area between the upper side of the top ring and the surface of the cured package, facilitating the smooth ejection of the cured package and reducing damage to the cured package.
[0019] Preferably, the outer side of the lower insert in the horizontal direction is set as a first conical surface, which tapers from bottom to top in the vertical direction, and the inner side of the top ring in the horizontal direction is set as a second conical surface, which is correspondingly set to the first conical surface and abuts against the first conical surface.
[0020] By adopting the above technical solution, the tapered surface helps to ensure the relative position between the top ring and the lower insert, ensuring that the top ring can be smoothly ejected from the disc armature. At the same time, it also helps to ensure that the top ring is locked in the die cavity during reset, reducing the occurrence of die bulging caused by overflow.
[0021] Preferably, the die cavity is cylindrical, and a conical overflow groove is provided on the upper side of the die cavity. The conical overflow groove and the core are coaxially arranged. When the mold is closed, the punch is embedded in the conical overflow groove, and the conical overflow groove shrinks from top to bottom to form a taper of about 2° to 3°.
[0022] By adopting the above technical solution, the tapered overflow groove is set with a taper on the upper side, so that the excess molten packaging material forms a flash after molding, which is convenient for workers to remove later.
[0023] In summary, this application has the following beneficial technical effects:
[0024] 1. By setting the curing encapsulation on both sides of the disc coil winding and the commutator, the curing encapsulation is formed by hot pressing of unsaturated polyester plastic sheet containing short glass fibers, which helps to improve the stability of the disc armature during operation, improves the overall structural strength and electrical performance of the armature, and is more suitable for high temperature, high speed and high intensity working environment;
[0025] 2. The cooperation between the die, the top ring, and the lower insert helps to ensure the quality of the curing and packaging, ensuring the consistency and accuracy of the curing and packaging, and helping to ensure the working quality of the packaging process;
[0026] 3. The combination of upper and lower heating plates and top rods and top rings driven by an automatic pressure forming machine helps to improve the automation level and work efficiency in the packaging process. Attached Figure Description
[0027] Figure 1 This is a half-sectional view that mainly illustrates the internal structure of the disc armature for a disc motor in this application;
[0028] Figure 2 This is a front view of the disc coil winding structure in the disc armature of the disc motor, which is the main feature of this application.
[0029] Figure 3 This is a sectional view in this application that mainly shows the internal structure of the packaging device in the mold-open state;
[0030] Figure 4 This is a cross-sectional view that mainly illustrates the internal structure of the packaging device in the mold-closed state in this application.
[0031] Reference numerals: 1. Commutator; 2. Disc-shaped coil winding; 21. Sector-shaped coil; 3. Curing encapsulation; 31. Pre-pressed sheet; 32. Outer edge protrusion; 33. Boss; 4. Upper heating plate; 41. Upper pad; 42. Upper template; 43. Guide post; 5. Punch; 51. Forming groove; 6. Lower heating plate; 61. Lower template; 62. Lower insert; 621. First conical surface; 622. Center hole; 7. Ejector rod; 8. Top ring; 81. Second conical surface; 82. Third conical surface; 9. Die; 91. Conical overflow groove; 92. Conical groove; 921. Fourth conical surface; 93. Die cavity. Detailed Implementation
[0032] The following is combined with Figure 1-4 This application is described in further detail.
[0033] This application discloses a disc-shaped armature for a disc motor and a packaging device thereof.
[0034] Example 1
[0035] See Figure 1 , Figure 2 The disc armature for the disc motor includes a commutator 1. A disc-shaped coil winding 2 is welded and fixed to the radial peripheral side of the upper end of the commutator 1. The disc-shaped coil winding 2 is formed by multiple sector coils 21 connected in series and interleaved around the commutator 1. Each sector coil 21 is made of self-adhesive enameled wire wound on an automatic winding machine using a winding die. After several sector coils 21 are wound, energize their two ends to electrically heat and shape them. The specific shape of the sector coil 21 is shown in [reference needed]. Figure 2 The outer side of the disc-shaped coil winding 2 is molded with a solidified encapsulation 3. A boss 33 is provided at the connection between the disc-shaped coil winding 2 and the commutator 1, with one boss 33 on each side of the solidified encapsulation 3 in the thickness direction. An outer edge protrusion 32 is also formed on the outer edge of the solidified encapsulation 3, located on the side of the disc-shaped coil winding 2 away from the commutator 1 in the thickness direction.
[0036] See Figure 3 Before hot pressing, two pre-pressed sheets 31 are respectively set on both sides of the disc coil winding 2 along the axis of the commutator 1. Each pre-pressed sheet 31 is cold-pressed into a ring-shaped thin sheet by unsaturated polyester plastic containing short glass fibers. The operator places the two pre-pressed sheets 31 and the disc coil winding 2 into the encapsulation device installed on the automatic pressure forming machine. The automatic pressure forming machine heats and pressurizes the encapsulation device to close it and maintain pressure, thereby melting and forming the two pre-pressed sheets 31 into a solidified encapsulation 3.
[0037] Example 2
[0038] See Figure 4The packaging device includes an upper heating plate 4 and a lower heating plate 6. The upper heating plate 4 and the lower heating plate 6 are respectively fixed on an automatic pressure forming machine. The upper heating plate 4 is relatively fixed, and the automatic pressure forming machine drives the lower heating plate 6 to move in the vertical direction, thereby completing the mold closing or mold opening.
[0039] An upper pad 41 is fixed to the lower side of the upper heating plate 4, and an upper template 42 is fixed to the lower side of the upper pad 41. Both the upper pad 41 and the upper template 42 are horizontally arranged. A punch 5 is fixed on the upper template 42. A guide post 43 is also fixed on the upper template 42, and the axis of the guide post 43 is vertically arranged.
[0040] A lower template 61 is fixed to the upper side of the lower heating plate 6, and the lower template 61 is horizontally positioned. A die 9 is fixed to the lower template 61. A conical overflow groove 91 is provided at the upper end of the die 9, and a die cavity 93 is provided at the bottom of the conical overflow groove 91. A conical groove 92 is provided at the bottom of the die cavity 93. The conical overflow groove 91, the die cavity 93, and the conical groove 92 are all coaxially arranged. In the mold-closed state, the punch 5 is inserted vertically into the conical overflow groove 91. A core is also fixed to the lower template 61, and the core penetrates the punch 5 vertically. When the commutator 1 with the welded disc coil winding 2 is placed in the die 9, the disc armature will be sleeved on the core, and the commutator 1 is coaxially arranged with the core. The conical overflow groove 91, the die cavity 93, and the conical groove 92 are all coaxially arranged with the core.
[0041] The guide post 43 penetrates the cavity 9 along its circumferential direction. The cavity 9 and the guide post 43 slide against each other. The side of the guide post 43 facing away from the lower mold plate 61 is formed with a spherical surface. The spherical surface helps to ensure that the guide post 43 is inserted into the cavity 9 when the mold is closed.
[0042] A lower insert 62 is fitted onto the core. Grooves corresponding to the upper boss 33 of the disc armature are formed on both the upper side of the lower insert 62 and the lower side of the punch 5. A center hole 622 is also formed on the lower insert 62, coaxially positioned with the core and fitted onto the outer side of the core. When the commutator 1 is placed on the lower insert 62, the lower end of the commutator 1 slides vertically into the center hole 622 and is embedded within it. The lower insert 62 is detachably fixed to the lower template 61 by screws. The lower insert 62 can be replaced as needed.
[0043] A top ring 8 is fitted around the outer side of the lower insert 62. The top ring 8 is located within the conical groove 92. The top ring 8 slides vertically with the die 9. The top ring 8 is coaxially arranged with the core, and the upper end face of the top ring 8 is on the same horizontal plane as the bottom surface of the die cavity 93. A push rod 7 is also provided on the lower heating plate 6. The push rod 7 passes vertically through the lower heating plate 6 and the lower template 61, and slides vertically with the lower heating plate 6 and the lower template 61. The push rod 7 is located between the outer edge protrusion 32 and the protrusion of the disc armature. Multiple push rods 7 are evenly spaced around the axis of the top ring 8; in this embodiment, three are provided. The upper end of any push rod 7 passes vertically into the top ring 8 and is threadedly connected to the top ring 8. The automatic pressure forming machine drives all push rods 7 to slide vertically simultaneously.
[0044] The outer side of the lower insert 62 in the horizontal direction is set as a first conical surface 621. The first conical surface 621 is set to taper from bottom to top in the vertical direction. The inner side of the top ring 8 in the horizontal direction is set as a second conical surface 81. The second conical surface 81 is coaxially set with the first conical surface 621 and abuts against the first conical surface 621.
[0045] The inner surface of the top ring 8 in the horizontal direction is set as a third conical surface 82, which tapers vertically from top to bottom. The inner surface of the conical groove 92 is set as a fourth conical surface 921. The conical groove 92 and the third conical surface 82 are coaxially arranged, and the third conical surface 82 and the second conical surface 81 are coaxially arranged. The third conical surface 82 abuts against the fourth conical surface 921. By setting the second conical surface 81 and the third conical surface 82 on the top ring 8, as well as the first conical surface 621 and the fourth conical surface 921 that cooperate with them, it helps to ensure the coaxiality between the top ring 8 and the core during the sliding process of the ejector pin 7 pushing the top ring 8. During the reset process of the top ring 8, it helps to ensure that the top ring 8 is locked in the cavity 9, reducing the occurrence of mold bulging caused by overflow.
[0046] In the mold-closed state, the concave mold is cylindrical, and the convex mold 5 is embedded in the conical overflow groove 91. The upper side wall of the conical overflow groove 91 tapers from top to bottom, forming a taper of about 2° to 3°. After mold closing, the excess molten pre-pressed sheet 31 forms a flash on the side wall of the conical overflow groove 91 after molding, which is convenient for workers to remove. A forming groove 51 is also provided on the lower edge of the convex mold 5. After mold closing, the forming groove 51 causes the edge of the solidified encapsulation 3 of the disc armature to form an outer edge protrusion 32.
[0047] The implementation principle of the disc armature and encapsulation device for a disc motor in Embodiments 1 and 2 of this application is as follows: Workers continuously wind enameled wire to form multiple sector-shaped coils 21, and weld these coils 21 onto the radially annular outer surface of the commutator 1 to form a disc-shaped coil winding 2. Workers fix the upper template 42 and lower template 61 of the encapsulation device onto the upper heating plate 4 and lower heating plate 6 of the automatic pressure forming machine, respectively. At this time, the punch 5 and die 9 are in an open state. Workers place two pre-pressed sheets 31 and the disc-shaped coil winding 2 into the die cavity 93, positioning the disc-shaped coil winding 2 between the two pre-pressed sheets 31. The automatic pressure forming machine is started, causing the punch 5 and die 9 to close. Simultaneously, the upper heating plate 4 and lower heating plate 6 heat the punch 5, die 9, and the pre-pressed sheets 31 between them, causing the pre-pressed sheets 31 to melt and solidify on both sides of the disc-shaped coil winding 2 to form a solidified encapsulation 3. After the curing and encapsulation 3 is formed, the staff operates the automatic pressure forming machine to drive the concave mold 9 to move away from the convex mold 5 until the convex mold 5 and the concave mold 9 are separated. The hydraulic cylinder in the automatic pressure forming machine pushes multiple ejector rods 7 to slide upwards at the same time, thereby pushing the top ring 8 to move upwards, so that the curing and encapsulation 3 is separated from the concave mold cavity 93, making it convenient for the staff to remove the encapsulated disc armature. The hydraulic cylinder in the automatic pressure forming machine drives the top ring 8 to move downwards through three ejector rods 7, thereby driving the top ring 8 to reset, making it convenient to continue encapsulating the next disc armature.
[0048] The above are all preferred embodiments of the present application, and are not intended to limit the scope of protection of the present application. Therefore, any equivalent changes made based on the structure, shape, and principle of the present application should be included in the scope of protection of the present application.
Claims
1. A disc-shaped armature for a disc motor, characterized in that: The commutator (1) is welded to the outside of the commutator (1) and a disc coil winding (2) is formed by multiple sector coils (21) connected in series and wound around each other. Any sector coil (21) is wound with enameled wire. Any adjacent enameled wires are self-adhesive after being heated and pressed. A plastic-molded curing package (3) is provided on the outside of the disc coil winding (2).
2. The disc armature for a disc motor according to claim 1, characterized in that: The curing encapsulation (3) includes two pre-pressed sheets (31) formed by cold pressing. The two pre-pressed sheets (31) are respectively disposed on both sides of the disc coil winding (2) along the axial direction of the commutator (1). Both pre-pressed sheets (31) are made of unsaturated polyester plastic sheets containing short glass fibers. The two pre-pressed sheets (31) are hot-pressed and cured on the upper end of the disc coil winding (2) and the commutator (1) by an automatic pressure forming machine.
3. The disc armature for a disc motor according to claim 1, characterized in that: The solidified encapsulation (3) includes an outer edge protrusion (32) for balancing and a boss (33) for enclosing the interconnecting wires of the upper end of the commutator (1) and the fan coil (21).
4. A packaging device for encapsulating a disc-shaped armature for a disc motor as described in any one of claims 2 or 3, characterized in that: The machine includes an upper heating plate (4) and a lower heating plate (6) fixed on an automatic pressure forming machine. A die (9) is fixed on the upper side of the lower heating plate (6). The disc coil winding (2) and two pre-pressing plates (31) on both sides are placed in the die (9). A lower insert (62) is detachably fixed at the bottom of the die (9). The pre-pressing plates (31) on the lower side are set on the upper side of the lower insert (62). A center hole (622) is also provided on the lower insert (62). The lower end of the commutator (1) slides and engages with the center hole (622) in the vertical direction. The lower end of the commutator (1) is embedded in the center hole (622). A punch (5) is fixed on the lower side of the upper heating plate (4). When the punch (5) and the die (9) are closed, the lower end of the punch (5) is embedded in the die (9).
5. The packaging device according to claim 4, characterized in that: The lower heating plate (6) is fixed with a lower template (61) on the upper side. A core is fixed on the lower template (61). The core is coaxially arranged with the commutator (1). The upper end of the core passes through the punch (5) in the vertical direction. The lower insert (62) is detachably fixed on the lower template (61).
6. The packaging device according to claim 5, characterized in that: The lower heating plate (6) is provided with a push rod (7) driven by an automatic pressure forming machine. The push rod (7) passes through the lower heating plate (6) in the vertical direction. A top ring (8) is fixed at the upper end of the push rod (7). The top ring (8) slides in the die (9) along the core axis. The lower insert (62) is embedded in the top ring (8). The top ring (8) is coaxial with the core.
7. The packaging device according to claim 6, characterized in that: The outer side of the lower insert (62) in the horizontal direction is set as a first conical surface (621), the first conical surface (621) shrinks from bottom to top in the vertical direction, and the inner side of the top ring (8) in the horizontal direction is set as a second conical surface (81), the second conical surface (81) is correspondingly set with the first conical surface (621) and abuts against the first conical surface (621).
8. The packaging device according to claim 5, characterized in that: The die cavity (9) is cylindrical, and a conical overflow groove (91) is provided on the upper side of the die cavity (9). The conical overflow groove (91) and the core are coaxially arranged. When the mold is closed, the punch (5) is embedded in the conical overflow groove (91). The conical overflow groove (91) shrinks from top to bottom, forming approximately 2 0 ~3 0 The taper.