An asymmetric span winding former

Abstract

The utility model relates to hollow cup motor technical field, concretely relates to a kind of asymmetric span winding framework, it includes body;The outer surface of the middle section of the body is used to wind coil;One end of the body is equipped with the mounting hole for being connected with external winding machine;The other end of the body is equipped with the assembly slot for being assembled with external fixed plug;The other end of the body is provided with at least two pressure relief grooves along the axial direction;The shape of the cross section of the body is convex polygon;The convex polygon includes left line segment group and right line segment group;Left line segment group and right line segment group are enclosed into the convex polygon;The vertical projection length of left line segment group is longer than the vertical projection length of right line segment group.The utility model adopts asymmetric span design, magnetic field distribution is uniform, reduces circulation loss, improves electromagnetic efficiency;Weight distribution is balanced, reduces rotor mechanical unbalance, improves motor operating stability.

Description

Technical Field

[0001] This utility model relates to the field of hollow cup motor technology, specifically to an asymmetric span winding frame. Background Technology

[0002] In the semi-winding process of hollow cup coils, the coil blank is usually first wound on a winding machine using a skeleton, then flattened by adhesive tape, and finally the flat wire blank is rolled into a cylinder and the joint is soldered with tin to connect the beginning and end of the coil to form a hollow cup structure.

[0003] When winding a hollow cup motor, a frame is needed to fix the shape and position of the winding. Currently, most motor windings on the market are wound with symmetrical spans of convex polygonal frames. However, the hollow coils wound with such frames exhibit asymmetrical characteristics due to the difference in the span between the inner and outer diameters.

[0004] This structural defect leads to two problems: ① Coil overlap and gaps cause uneven mechanical weight distribution, significantly increasing the mechanical imbalance of the brushed motor rotor; ② Uneven magnetic field distribution causes internal circulating current, which consumes additional electrical energy and reduces motor efficiency. Summary of the Invention

[0005] The purpose of this invention is to overcome the above-mentioned shortcomings and provide an asymmetric span winding skeleton.

[0006] To achieve the above objectives, the specific solution of this utility model is as follows: an asymmetric span winding frame, comprising a body; the outer surface of the middle section of the body is used for winding coils; one end of the body is provided with a mounting hole for connecting to an external winding machine; the other end of the body is provided with an assembly groove for assembling with an external fixing plug; at least two pressure-reducing grooves are provided along the axial direction at the other end of the body; the cross-sectional shape of the body is a convex polygon; the convex polygon includes a left segment group and a right segment group; the left segment group and the right segment group enclose the convex polygon;

[0007] The vertical projection length of the left line segment group is longer than the vertical projection length of the right line segment group.

[0008] The present invention is further configured such that the convex polygon is hexagonal in shape; the number of pressure-reducing grooves is two; the left segment group includes a left first segment, a left second segment, and a left third segment connected end to end; the right segment group includes a right first segment, a right second segment, and a right third segment connected end to end; the left first segment is connected to the right first segment; the left third segment is connected to the right third segment; the left second segment, the right second segment, and the two pressure-reducing grooves are arranged parallel to each other; one of the pressure-reducing grooves passes through the left first segment and the left third segment; the other pressure-reducing groove passes through the right first segment and the right third segment.

[0009] The present invention is further configured such that the convex polygon is a quadrilateral or an octagon.

[0010] The present invention is further configured such that the vertical projection length of the right line segment group is the inner diameter side span Kn; the vertical projection length of the left line segment group is the outer diameter side span Kw; the sum of the inner diameter side span Kn and the outer diameter side span Kw is the total span Kz; satisfying the following formula:

[0011] Coil thickness h = (Dd) / 2;

[0012] Total span Kz = (D+d)π / 2 / z*eh;

[0013] Inner diameter side span distance Kn=dπ / z-(Dd) / 2;

[0014] The outer diameter span distance Kw = Kz - Kn;

[0015] Where D is the outermost circumference diameter of the coil blank after passing through the unwinding drum; d is the diameter of the inner hollow part of the coil blank after winding; e is the span coefficient; h is the wall thickness of the coil blank after winding; and z is the number of magnetic poles of the hollow cup motor.

[0016] The present invention is further configured such that each of the pressure-reducing grooves has a first pressure-reducing arc at its end.

[0017] The present invention is further configured such that a second pressure-reducing arc is provided on the outer surface of one end of the body.

[0018] The beneficial effects of this invention are as follows: By setting an asymmetrical span in the overall frame structure, the coil naturally fits the drum after unwinding, avoiding overlap, improving inter-turn insulation performance, enhancing product reliability and consistency, and reducing the defect rate. The asymmetrical frame design ensures consistent coil turn spacing, reducing magnetic field distortion caused by structural unevenness, decreasing internal circulating current losses, and improving electromagnetic conversion efficiency. Furthermore, the balanced coil weight distribution reduces mass shift caused by overlap or gaps, lowering rotor mechanical imbalance, improving motor operating stability, reducing energy loss and mechanical wear due to vibration, and extending motor life. Attached Figure Description

[0019] The utility model will be further described with reference to the accompanying drawings, but the embodiments in the drawings do not constitute any limitation on the present utility model. For those skilled in the art, other drawings can be obtained based on the following drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0021] Figure 2 This is a schematic diagram of the overall structure of the present invention from another perspective;

[0022] Figure 3 This is a side view of the present invention;

[0023] Figure 4 This is a cross-sectional view of the present invention;

[0024] Figure 5 This is a cross-sectional view of the coil blank after it has passed through the drum.

[0025] The components are: 1. Body; 2. Mounting hole; 3. Coil blank; 4. Assembly slot; 5. Pressure reducing slot; 6. Left segment group; 61. Left first segment; 62. Left second segment; 63. Left third segment; 7. Right segment group; 71. Right first segment; 72. Right second segment; 73. Right third segment; 81. First pressure reducing arc; 82. Second pressure reducing arc. Detailed Implementation

[0026] To facilitate understanding of the present invention, a more complete description will be given below with reference to the accompanying drawings. Preferred embodiments of the invention are shown in the drawings. However, the invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a thorough and complete understanding of the disclosure of the invention. It should be noted that when an element is referred to as being "fixed to" another element, it can be directly on the other element or there may be an intervening element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "left," "right," and similar expressions used herein are for illustrative purposes only.

[0027] like Figure 1-5 As shown, an asymmetric span winding frame of this embodiment includes a body 1; the outer surface of the middle section of the body 1 is used for winding coils; one end of the body 1 is provided with a mounting hole 2 for connecting with an external winding machine; the other end of the body 1 is provided with a mounting groove 4 for assembling with an external fixing plug; at least two pressure reducing grooves 5 are provided along the axial direction at the other end of the body 1; the cross-sectional shape of the body 1 is a convex polygon; the convex polygon includes a left line segment group 6 and a right line segment group 7; the left line segment group 6 and the right line segment group 7 enclose the convex polygon;

[0028] The vertical projection length of the left line segment group 6 is longer than the vertical projection length of the right line segment group 7.

[0029] In actual production, the outer surface of the middle section of the main body 1 is used for winding the coil; the bobbin material is usually an insulating material to prevent short circuits and ensure electrical safety. By setting the pressure-reducing groove 5, the coil tension during winding will cause radial expansion stress in the bobbin. The pressure-reducing groove 5 weakens the local stiffness and concentrates the stress in the groove, avoiding overall deformation of the bobbin. The mounting hole 2 is used to connect with an external winding machine, serving as a fixation and driving function, facilitating automated winding. During winding, the external fixing plug is assembled with the mounting groove 4, which can prevent bobbin deformation during winding and ensure the shape of the coil. After winding is completed, the external fixing plug can be removed, and the coil blank 3 can be quickly removed from the bobbin while ensuring that the coil shape is not deformed. When the removed coil blank 3 undergoes the flattening process, it is necessary to ensure that the right half of the coil with the shorter span is used as the inner coil in the winding stage to ensure better performance.

[0030] By implementing an asymmetrical span design in the overall structure of the coil frame, the coil, after unwinding, naturally conforms to the drum, avoiding overlap, improving inter-turn insulation performance, enhancing product reliability and consistency, and reducing the defect rate. The asymmetrical frame design ensures a more uniform coil turn spacing, effectively eliminating magnetic field distortion caused by uneven coil structure. After flattening and winding processes, the coil blank 3, wound with this frame, exhibits a more uniform magnetic field distribution, reducing internal circulating current losses and improving electromagnetic conversion efficiency. Simultaneously, the more balanced coil weight distribution reduces mass shift caused by overlap or gaps, thereby lowering rotor mechanical imbalance. This not only improves motor operational stability but also significantly reduces energy loss and mechanical wear caused by vibration, extending motor life. More effective copper material can be accommodated within the same volume, increasing the motor's power density and meeting the development trend of high power and miniaturization.

[0031] like Figure 1-5 As shown in the figure, in this embodiment, an asymmetric span winding skeleton is provided. The convex polygon is hexagonal in shape. There are two pressure-reducing grooves 5. The left segment group 6 includes a left segment 61, a left second segment 62, and a left third segment 63 connected end to end. The right segment group 7 includes a right segment 71, a right second segment 72, and a right third segment 73 connected end to end. The left segment 61 is connected to the right segment 71. The left third segment 63 is connected to the right third segment 73. The left second segment 62, the right second segment 72, and the two pressure-reducing grooves 5 are arranged parallel to each other. One pressure-reducing groove 5 passes through the left segment 61 and the left third segment 63. The other pressure-reducing groove 5 passes through the right segment 71 and the right third segment 73.

[0032] Specifically, the asymmetrical span setting achieves uniform spacing between turns after the coil is unrolled, eliminating overlap and gaps. Simultaneously, the asymmetrical design of the left and right segment groups 7 improves the fit of the coil's beginning and end transition areas, preventing overlap at the coil's ends. The parallel arrangement of the left two segments 62, right two segments 72, and pressure-reducing groove 5 makes the coil blank 3 unfold more smoothly, reducing internal stress concentration, increasing wire filling density, improving motor power density, and maximizing space utilization.

[0033] like Figure 1-5 As shown in this embodiment, an asymmetric span winding skeleton has the following characteristics: the vertical projection length of the right segment group 7 is the inner diameter side span Kn; the vertical projection length of the left segment group 6 is the outer diameter side span Kw; the sum of the inner diameter side span Kn and the outer diameter side span Kw is the total span Kz; satisfying the following formula:

[0034] Coil thickness h = (Dd) / 2;

[0035] Total span Kz = (D+d)π / 2 / z*eh;

[0036] Inner diameter side span distance Kn=dπ / z-(Dd) / 2;

[0037] The outer diameter span distance Kw = Kz - Kn;

[0038] Where D is the outermost circumference diameter of coil blank 3 after it passes through the unwinding drum; d is the diameter of the inner hollow part of coil blank 3 after it is wound into the drum; e is the span coefficient; h is the wall thickness of coil blank 3 after it is wound into the drum; and z is the number of magnetic poles of the hollow cup motor.

[0039] Specifically, the coil thickness h is the distance from the inner circle to the outer circle after the coil blank 3 is wound into a coil, which affects the mechanical strength and space utilization of the coil. The span coefficient e is a common parameter in the industry. When the span is full, e is usually set to 1 to adjust the coil span. When the span is short, e < 1, and when the span is long, e > 1. In actual design, the height of the convex polygon is usually made to be consistent with the height H of the coil blank 3.

[0040] Under the conditions described above, in actual production, the cross-sectional shape of the skeleton can be made into a quadrilateral, pentagon, hexagon, or octagon shape, depending on actual needs.

[0041] like Figure 1-5 As shown in the figure, in this embodiment of an asymmetric span winding frame, each of the pressure-reducing grooves 5 has a first pressure-reducing arc 81 at its end. The outer surface of one end of the body 1 has a second pressure-reducing arc 82.

[0042] By setting the first pressure-reducing arc 81 and the second pressure-reducing arc 82, the stress concentration at the opening of the pressure-reducing groove 5 is alleviated through a circular arc transition, preventing the skeleton from cracking (the stress concentration factor can be reduced by more than 50%). This reduces the frictional resistance of the groove opening to the coil, protects the wire insulation layer, and reduces the demolding force by 30%-40%.

[0043] The above description is only a preferred embodiment of the present utility model. Therefore, any equivalent changes or modifications made to the structure, features and principles described in the claims of the present utility model patent application are included within the protection scope of the present utility model patent application.

Claims

1. An asymmetric span winding former, characterized by: The device includes a body (1); the outer surface of the middle section of the body (1) is used for winding coils; one end of the body (1) is provided with a mounting hole (2) for connecting with an external winding machine; the other end of the body (1) is provided with an assembly groove (4) for assembling with an external fixing plug; at least two pressure-reducing grooves (5) are provided along the axial direction at the other end of the body (1); the cross-sectional shape of the body (1) is a convex polygon; the convex polygon includes a left line segment group (6) and a right line segment group (7); the left line segment group (6) and the right line segment group (7) form the convex polygon; The vertical projection length of the left line segment group (6) is longer than the vertical projection length of the right line segment group (7).

2. An asymmetric span winding former according to claim 1, characterized in that: The convex polygon is hexagonal in shape; the number of pressure-reducing grooves (5) is two; The left segment group (6) includes a left segment 1 (61), a left segment 2 (62), and a left segment 3 (63) that are connected end to end; The right segment group (7) includes a right segment 1 (71), a right segment 2 (72), and a right segment 3 (73) that are connected end to end; The left segment (61) is connected to the right segment (71); the left three segments (63) are connected to the right three segments (73); The left two sections (62), the right two sections (72), and the two pressure-reducing grooves (5) are arranged in parallel to each other; One of the pressure relief grooves (5) is provided through the left first section (61) and the left third section (63); Another pressure relief groove (5) is provided through the right first section (71) and the right third section (73).

3. An asymmetric span winding former according to claim 1, characterized in that: The convex polygon is a quadrilateral or an octagon.

4. An asymmetric span winding frame according to any one of claims 1-3, characterized in that: The vertical projection length of the right line segment group (7) is the inner diameter side span Kn; The vertical projection length of the left line segment group (6) is the outer diameter side span Kw; The sum of the inner diameter side span Kn and the outer diameter side span Kw is the total span Kz; Satisfy the following formula: Coil thickness h = (Dd) / 2; Total span Kz = (D+d)π / 2 / z*eh; Inner diameter side span distance Kn=dπ / z-(Dd) / 2; The outer diameter span distance Kw = Kz - Kn; Where D is the outermost circumference diameter of the coil blank (3) after it passes through the unwinding drum; d is the diameter of the inner hollow part of the coil blank (3) after it is wound into the drum; e is the span coefficient; h is the wall thickness of the coil blank (3) after it is wound into the drum; and z is the number of magnetic poles of the hollow cup motor.

5. An asymmetric span former according to claim 1, wherein: Each of the pressure-reducing grooves (5) is provided with a first pressure-reducing arc (81) at its end.

6. An asymmetric span former according to claim 1, wherein: The outer surface of one end of the body (1) is provided with a second decompression arc (82).

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