A mover coil, an induction module and a coreless motor

Abstract

The utility model relates to the technical field of coil winding, especially to a kind of mover coil, induction module and iron-coreless motor, and its technical scheme main point includes: first coil group;Second coil group, the side of the first coil group is crossed and stacked to the second coil group, and the end of the first coil group and the end of the second coil group partially coincide, to form first press bending area;And third coil group, located the side of the second coil group away from the first coil group, the side of the third coil group is crossed and stacked in the second coil group, and the end of the second coil group and the end of the third coil group partially coincide, to form second press bending area, the first press bending area and the second press bending area do not intersect each other, the present application can reduce the possibility that coil group produces cracking, fracture in processing process.

Description

Technical Field

[0001] This utility model relates to the technical field of coil windings, and in particular to a mover coil, an induction module, and a coreless motor. Background Technology

[0002] Coreless motors are a type of motor design that optimizes performance by eliminating the iron core structure (such as silicon steel sheets) found in traditional motors. They are primarily used in applications where efficiency, weight, and response speed are critical. Thanks to their high efficiency, rapid response, and lightweight advantages, they hold an important position in high-end precision fields.

[0003] The core component of a coreless motor includes a mover coil, which adopts a three-phase winding structure. Specifically, the mover coil includes three coil groups, which are approximately rectangular ring structures. By stacking the three coil groups one after another and pressing their ends together, a mover coil is formed. The mover coil and the magnetic track in the motor generate motion based on the principle of electromagnetic induction.

[0004] However, existing mover coils still have many shortcomings. For example, in the actual molding process of the mover coil, three coils need to be placed into the corresponding molds, and then the ends of the coil group are pressed together by the molds. During this process, the ends of the coil group also need to be bent to one side to adapt to the spatial design requirements of the mover coil. However, in the above process, because the bending range is too large, the coil is prone to cracking or even breaking. There is currently a lack of a mover coil solution that can meet the conditions of large bending. Therefore, the existing technology needs to be improved.

[0005] The above information is provided as background information only to aid in understanding this disclosure and does not constitute an assertion or admission that any of the above content can be used as prior art relative to this disclosure. Utility Model Content

[0006] This invention provides a moving coil, an induction module, and a coreless motor to solve the problem of easy cracking and breakage of coil assemblies in the prior art.

[0007] To achieve the above objectives, in a first aspect, this utility model provides a moving coil employing the following technical solution:

[0008] A moving coil, comprising:

[0009] First coil group;

[0010] The second coil group has one side of the first coil group stacked crosswise into the second coil group, and the ends of the first coil group and the ends of the second coil group partially overlap to form a first bending area;

[0011] And a third coil group, located on the side of the second coil group away from the first coil group, with one side of the third coil group stacked crosswise within the second coil group, and the ends of the second coil group and the ends of the third coil group partially overlapping to form a second bending region, wherein the first bending region and the second bending region do not intersect each other.

[0012] Preferably, a first clearance gap is formed between the first coil group and the second coil group, and the first clearance gap is used to allow the third coil group of another moving coil to be cross-stacked;

[0013] A second clearance gap is formed between the second coil group and the third coil group, and the second clearance gap is used to allow the first coil group of another moving coil to be cross-stacked.

[0014] When the first coil group and the third coil group are stacked together, their ends partially overlap and form a third bending region, which does not intersect with the first bending region and the second bending region.

[0015] Preferably, the bending angle α of the first bending region, the second bending region, and the third bending region is in the range of 40°≤α≤90°.

[0016] Preferably, the thickness of the first coil group, the second coil group, and the third coil group is ≤6mm.

[0017] Preferably, the width D of the first coil group, the second coil group, and the third coil group and their respective single-side width d satisfy the following relationship: D=4d.

[0018] Preferably, the first coil group, the second coil group, and the third coil group are configured as two groups facing away from each other and mirroring each other.

[0019] Secondly, this utility model provides a sensing module with the following technical solution:

[0020] An induction module includes a mover coil and a permanent magnet stator disposed opposite to the mover coil.

[0021] Preferably, the permanent magnet stator includes a plurality of permanent magnet blocks arranged sequentially at intervals along a straight line, and the pole spacing of the permanent magnet blocks is 30mm-84mm.

[0022] Preferably, the thrust fluctuation rate between the moving coil and the permanent magnet stator is 0.84%-2.1%.

[0023] Thirdly, this utility model provides a coreless motor using the following technical solution:

[0024] A coreless motor includes an induction module and a motor body, wherein the induction module is disposed on the motor body.

[0025] Compared with the prior art, the present invention has the following beneficial effects:

[0026] The moving coil, induction module, and coreless motor provided by this utility model, by stacking the first coil group, the second coil group, and the third coil group in pairs, reduce the bending part from the original three layers to two layers, and change one three-layer bend to two bends, which greatly reduces the difficulty of bending and solves the problem of coil group cracking and breaking.

[0027] This invention has other features and advantages that will be apparent from or will be set forth in detail in the accompanying drawings and the following detailed description, which together serve to explain the particular principles of this invention. Attached Figure Description

[0028] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0029] Figure 1 This is a schematic diagram of a structure in which the moving coils are arranged in a close configuration;

[0030] Figure 2 This is a schematic diagram of the structure after the lower end of the mover coil is pressed together using a tightly arranged arrangement.

[0031] Figure 3 This is a schematic diagram of the structure of the moving coil with a staggered arrangement provided in this embodiment of the utility model;

[0032] Figure 4 This is a schematic diagram of the structure of the moving coil after the lower end is pressed together in a staggered arrangement according to an embodiment of the present invention;

[0033] Figure 5 This is a structural schematic diagram of the moving coil from another perspective provided in an embodiment of the present invention;

[0034] Figure 6 This is a schematic diagram of the structure of two moving coils overlapping each other according to an embodiment of the present invention;

[0035] Figure 7This is a schematic diagram of the structure provided in this embodiment of the present invention, showing two moving coils arranged back-to-back in a mirror image.

[0036] Figure 8 This is a schematic diagram of the structure of the sensing module provided in this embodiment of the utility model.

[0037] Figure label:

[0038] 1001. Moving coil; 1002. Permanent magnet stator; 1. First coil group; 2. Second coil group; 3. Third coil group; 4. First bending area; 5. Second bending area; 6. Third bending area; 7. First clearance gap; 8. Second clearance gap. Detailed Implementation

[0039] To make the objectives, features, and advantages of this utility model more apparent and understandable, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described below are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0040] In the description of this utility model, it should be understood that when a component is considered to be "connected" to another component, it can be directly connected to the other component or there may be a component that is centrally positioned therein. When a component is considered to be "set" on another component, it can be directly set on the other component or there may be a component that is centrally positioned therein.

[0041] Furthermore, terms such as "long," "short," "inner," and "outer" indicate orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings. They are used only for the convenience of describing this utility model and do not indicate or imply that the device or component referred to must have this specific orientation or operate in a specific orientational configuration. Therefore, they should not be construed as limitations of this utility model.

[0042] Reference Figure 1 and Figure 2 The structure is a conventional three-phase mover coil stack, consisting of three coil groups arranged closely together and overlapping each other, with the ends of the three coil groups coinciding in the thickness direction. Therefore, during the bending process of the coil group ends, all three coil groups need to be bent simultaneously at the same location. However, due to the excessive structural thickness, stress concentration occurs at the bending points, leading to cracking and breakage of the coil groups. Therefore, an improvement is needed.

[0043] Based on this, the following is in conjunction with the appendix Figure 3-8The technical solution of this utility model will be further illustrated through specific implementation methods.

[0044] Example 1:

[0045] Please refer to Figure 3 This utility model embodiment provides a moving coil 1001 to solve the cracking and breakage that occurs when coil groups are stacked. Specifically, the moving coil 1001 mainly includes: a first coil group 1, a second coil group 2 and a third coil group 3. Unlike the conventional arrangement, this embodiment provides a staggered arrangement scheme.

[0046] Specifically, in combination Figure 4 In this embodiment, the first coil group 1, the second coil group 2, and the third coil group 3 have a rectangular hollow ring-shaped outline, and according to the attached... Figure 1 The perspectives are arranged sequentially from left to right; wherein, one side of the first coil group 1 is stacked crosswise into the second coil group 2, and the end of the first coil group 1 and the end of the second coil group 2 partially overlap to form the first bending region 4.

[0047] Meanwhile, the third coil group 3 is located on the side of the second coil group 2 away from the first coil group 1. One side of the third coil group 3 is stacked crosswise within the second coil group 2, and the ends of the second coil group 2 and the ends of the third coil group 3 partially overlap to form the second bending region 5. The first bending region 4 and the second bending region 5 do not intersect each other.

[0048] By adopting the above-mentioned arrangement, when bending the moving coil 1001, the first bending area 4 and the second bending area 5 can be bent separately. Compared with the method of bending three layers at once, the staggered arrangement adopted in this solution can distribute the bending thickness of a single bending, thereby reducing the stress in the bending area, reducing the possibility of coil group cracking and breakage, and optimizing the forming quality of the moving coil 1001.

[0049] Understandably, in practical applications, the ends of the first coil group 1, the second coil group 2, and the third coil group 3 can be bent to obtain a moving coil 1001 structure with a flat middle and raised ends. This can optimize space, adapt to compact design, adapt to motion trajectory or manufacturing process requirements, and facilitate subsequent assembly and layout.

[0050] Furthermore, continue to refer to Figure 4To meet the linear motion requirements of the motor, multiple moving coils 1001 are typically arranged in parallel. To allow different moving coils 1001 to be combined, a first clearance gap 7 is formed between the first coil group 1 and the second coil group 2, allowing the third coil group 3 of another moving coil 1001 to cross-over. Simultaneously, a second clearance gap 8 is formed between the second coil group 2 and the third coil group 3, allowing the first coil group 1 of another moving coil 1001 to cross-over, ensuring a tight connection between the different moving coils 1001 and a compact structure.

[0051] Based on the above settings, refer to Figure 5 and Figure 6 When the first coil group 1 and the third coil group 3 are stacked together, the ends of the first coil group 1 and the third coil group 3 partially overlap and form a third bending region 6. The third bending region 6 does not intersect with the first bending region 4 and the second bending region 5 respectively. At this time, it is equivalent to only need to bend the third bending region 6 to crosslink the different moving coils 1001 together and realize the overall assembly of multiple moving coils 1001.

[0052] In one alternative embodiment, multiple sets of cross-linked first coil group 1, second coil group 2 and third coil group 3 can be simultaneously placed into the mold and subjected to concentrated bending processing. In this way, the overall thickness of the first bending area 4, the second bending area 5 and the third bending area 6 will not be too high, thereby enabling efficient and stable bending of the mover coil 1001.

[0053] Furthermore, referring to Figure 7 The bending angle α of the first bending region 4, the second bending region 5, and the third bending region 6 is in the range of 40°≤α≤90°.

[0054] It is understandable that the bending angle can be understood as the angle formed by the flat part in the middle of the moving coil 1001 and the raised part at the end. At this time, because this solution adopts a staggered arrangement, the overall thickness during bending is reduced, so the bending angle of the coil can also be expanded. When the coil angle is expanded, the overall length of the coil can be effectively shortened, thereby making the structure more compact.

[0055] It should be explained that when the bending angle α is less than 40°, the length of the bent mover coil 1001 may be too large due to the small bending angle, which may cause the mover coil 1001 to fail to meet the design requirements. When the bending angle α is greater than 90°, the coil may crack or break due to the excessive bending angle. The closer the bending angle is to 90°, the more compact the overall length of the coil has become. When the bending angle is 90°, it can meet the design requirements. Therefore, by controlling the bending angle α between 40°≤α≤90°, the overall length of the mover coil 1001 can be further reduced, and the structural compactness in its length direction can be improved.

[0056] For example, the bending angle can be 40°, 50°, 60°, 70°, 80° or 90°. There is no limitation on the bending angle. In another embodiment, the value of the bending angle can be selected between any two of the above parameter values.

[0057] Furthermore, the thickness of the first coil group 1, the second coil group 2, and the third coil group 3 is ≤6mm. Experiments show that when the thickness is greater than 6mm, cracking or breakage is more likely to occur during bending; when the thickness is less than 6mm, the likelihood of cracking or breakage in the coil group is greatly reduced.

[0058] For example, the thickness is defined as n, and the value of n can be 1mm, 2mm, 3mm, 4mm, 5mm, or 6mm, etc. There is no restriction on the specific value of the thickness. In another embodiment, the value of the thickness can also be selected between any two of the above parameter values.

[0059] Furthermore, looking back Figure 4 To make the first coil group 1, the second coil group 2, and the third coil group 3 more compact when stacked, taking the first coil group 1 as an example, we select its overall width and define it as D, and select its single-side width and define it as d. The width D of the first coil group 1, the second coil group 2, and the third coil group 3 and their respective single-side width d satisfy the following relationship: D=4d.

[0060] Based on the above settings, when the first coil group 1, the second coil group 2, and the third coil group 3 are stacked, their single sides can be placed close together in sequence, which can further optimize the overall spatial layout during arrangement and improve its structural compactness.

[0061] It is understood that d is usually 8mm, 10mm, 14mm or 18mm, etc. The specific value of d can be adjusted according to actual needs, and no specific restrictions are made here. In this embodiment, d is selected as 10mm as an example.

[0062] Furthermore, referring to Figure 6 The first coil group 1, the second coil group 2, and the third coil group 3 are configured as two sets facing each other in a mirror image. Based on the above configuration, the two sets of first coil group 1, second coil group 2, and third coil group 3 arranged facing each other in a mirror image can increase energy density, which is beneficial to improving thrust.

[0063] This embodiment has the following beneficial effects:

[0064] 1. By adopting a staggered arrangement scheme, the overall thickness during a single bend can be reduced, thereby reducing the possibility of cracking or breakage of the coil assembly and meeting the processing requirements under conditions of large-amplitude bending.

[0065] 2. By setting the relationship between the width of one side and the overall width to D=4d, the first coil group 1, the second coil group 2 and the third coil group 3 are stacked compactly;

[0066] 3. The two sets of first coil group 1, second coil group 2 and third coil group 3, which are back-to-back and mirror images, can increase the energy density in a limited space, thereby obtaining greater thrust.

[0067] Example 2:

[0068] Based on Example 1, features not explained in this example will be explained using the methods described in Example 1, and will not be repeated here. The difference between this example and Example 1 is that: (Refer to...) Figure 8 An induction module is provided, including the mover coil 1001 in Embodiment 1, and a permanent magnet stator 1002 disposed opposite to the mover coil 1001.

[0069] When current is passed through the moving coil 1001, it interacts with the periodically distributed alternating magnetic field generated by the permanent magnet stator 1002 under the action of electromagnetic induction, and generates Lorentz force. During this process, the phase difference of the three-phase current causes the coils at different positions to form a continuous thrust in the magnetic field. By controlling the amplitude and phase of the current, the magnitude and direction of the thrust can be precisely adjusted, driving the moving coil 1001 to move linearly along the guide rail. The operating principle between the moving coil 1001 and the permanent magnet stator 1002 will not be described in detail here.

[0070] Furthermore, the permanent magnet stator 1002 includes multiple permanent magnet blocks arranged sequentially at intervals along a straight line. The permanent magnet blocks can be neodymium iron boron magnets. Multiple permanent magnet blocks can form a periodically changing magnetic field. Based on this, the pole spacing of the permanent magnet blocks is 30mm-84mm.

[0071] The specific setting of the pole pitch is related to the overall dimensions of the induction module and the motor. The pole pitch is the distance between the same magnetic poles in a certain phase of the motor, that is, the distance between two adjacent magnetic poles in the same phase. When the pole pitch is less than 30mm, there may be a problem of the pole pitch being too small, resulting in the coil group being too large in size, the overall structure of the induction module being uncoordinated, and thus the size ratio of the motor being unbalanced. When the pole pitch is greater than 84mm, it may result in the overall size of the induction module being too large, wasting structural space, resulting in the size ratio of the motor being unbalanced, and failing to meet the assembly scenario of the motor in a compact space. Therefore, when the pole pitch of the permanent magnet block is 30mm-84mm, an induction module with a coordinated size ratio can be obtained, which can meet the compact assembly requirements and enable the motor to meet the specification design requirements.

[0072] For example, the pole pitch of the permanent magnet block can be 30mm, 60mm, 72mm or 84mm. The specific value of the pole pitch can be adjusted according to actual needs, and no specific limitation is made here. In another embodiment, the range of the pole pitch value can also be selected between any two of the above parameter values.

[0073] Furthermore, given the limitations of thickness and dimensions, the staggered arrangement scheme employed in this design significantly improves thrust fluctuation rate compared to a close arrangement. Specifically, the thrust fluctuation rate between the mover coil 1001 and the permanent magnet stator 1002 is 0.84%-2.1%, a range determined experimentally. The following tests were conducted on the induction module under different parameter conditions, and the results are shown in Table 1.

[0074]

[0075] Table 1

[0076] Based on the above tests, it can be seen that as the pole pitch increases, the thrust also gradually increases. Under the condition that the size, thickness and pole pitch remain unchanged, the thrust obtained by the staggered moving coil 1001 and the tightly arranged moving coil 1001 is the same. pk2pk represents the difference between the maximum peak value and the minimum value of thrust during a test period. Based on this, the thrust fluctuation rate = pk2pk / Fx. As can be seen from the above tests, the thrust output of the staggered moving coil 1001 is more stable than that of the tightly arranged moving coil 1001.

[0077] Example 3:

[0078] This embodiment provides a coreless motor, including the induction module from Embodiment 2, and a motor body, with the induction module mounted on the motor body. Specifically, the outer side of the mover coil 1001 can be wrapped with an epoxy resin layer to encapsulate and form an I-shaped profile. Two sets of permanent magnet stators 1002 are configured, located on either side of the mover coil 1001. Based on this, the motor body includes a guide rail and a drive power supply. The permanent magnet stators 1002 and the mover coil 1001 are respectively mounted on the guide rail, and the mover coil 1001 is connected to the drive power supply. The specific structure of the motor body will not be described in detail here. Through the above configuration, a coreless motor with small thrust fluctuations and coil group that is not prone to cracking or breakage can be obtained.

[0079] Therefore, the above embodiments are only used to illustrate the technical solutions of this utility model, and not to limit it. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model.

Claims

1. A moving coil, characterized in that, include: First coil group (1); The second coil group (2) has one side of the first coil group (1) stacked crosswise into the second coil group (2), and the end of the first coil group (1) partially overlaps with the end of the second coil group (2) to form a first bending region (4). And a third coil group (3) is located on the side of the second coil group (2) away from the first coil group (1). One side of the third coil group (3) is stacked crosswise within the second coil group (2), and the end of the second coil group (2) partially overlaps with the end of the third coil group (3) to form a second bending region (5). The first bending region (4) and the second bending region (5) do not intersect each other.

2. The moving coil according to claim 1, characterized in that, A first clearance gap (7) is formed between the first coil group (1) and the second coil group (2), and the first clearance gap (7) is used to allow the third coil group (3) of another moving coil (1001) to be cross-stacked; A second clearance gap (8) is formed between the second coil group (2) and the third coil group (3), and the second clearance gap (8) is used for the first coil group (1) of another moving coil (1001) to be cross-stacked; When the first coil group (1) and the third coil group (3) are stacked together, their ends partially overlap and form a third bending region (6), which does not intersect with the first bending region (4) and the second bending region (5).

3. The moving coil according to claim 2, characterized in that, The bending angle α of the first bending region (4), the second bending region (5) and the third bending region (6) ranges from 40°≤α≤90°.

4. The moving coil according to claim 1, characterized in that, The thickness of the first coil group (1), the second coil group (2) and the third coil group (3) is ≤6mm.

5. The moving coil according to claim 1, characterized in that, The width D of the first coil group (1), the second coil group (2) and the third coil group (3) and their respective single-side width d satisfy the following relationship: D=4d.

6. The moving coil according to any one of claims 1-5, characterized in that, The first coil group (1), the second coil group (2), and the third coil group (3) are configured as two groups facing each other in a mirror image.

7. A sensing module, characterized in that, It includes a mover coil (1001) as described in any one of claims 1-6, and a permanent magnet stator (1002) disposed opposite to the mover coil (1001).

8. The sensing module according to claim 7, characterized in that, The permanent magnet stator (1002) includes a plurality of permanent magnet blocks arranged sequentially at intervals along a straight line, and the pole spacing of the permanent magnet blocks is 30mm-84mm.

9. The sensing module according to claim 8, characterized in that, The thrust fluctuation rate between the moving coil (1001) and the permanent magnet stator (1002) is 0.84%-2.1%.

10. A coreless motor, characterized in that, The device includes the sensing module as described in claim 7, and also includes a motor body, wherein the sensing module is disposed on the motor body.

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