A stator lamination for a brushless hollow cup motor lamination stator structure

Abstract

The utility model relates to a brushless hollow cup motor field especially a kind of brushless hollow cup motor lamination winding stator structure with stator lamination winding. A kind of brushless hollow cup motor lamination winding stator structure with stator lamination winding, including stator lamination winding main body selects self-adhesion enameled wire, every phase winding of stator lamination winding includes a first group winding wound in clockwise direction and a second group winding wound in counterclockwise, by winding starting wire winding completion first winding, then transition to the second winding of reverse winding by winding wire, finally in winding tail wire end. The utility model has the advantages that: brushless hollow cup motor stator lamination winding: every phase winding includes a first group winding wound in clockwise direction and a second group winding wound in counterclockwise, ensure that the adjacent edge current direction of every phase winding is consistent;The adjacent edge of every phase winding is close and distributed in parallel, which is conducive to controlling the inner diameter size and roundness of stator winding after winding shaping.

Description

Technical Field

[0001] This utility model relates to the field of brushless hollow cup motors, and in particular to a stator lap winding for a brushless hollow cup motor stator structure. Background Technology

[0002] Traditionally, in most electric motors, the inner circumference of the stator laminations has multiple evenly distributed radial teeth, with adjacent teeth naturally forming corresponding slots. The windings straddle these stator teeth. On one hand, the stator teeth occupy the effective winding area within the stator, affecting the slot fill factor of the stator windings, reducing current density, and thus impacting motor efficiency. On the other hand, due to the presence of stator tooth tips, to ensure the air gap between the rotor and the stator's inner circumference, the rotor's outer diameter must be small, thus affecting the motor's output power and torque. The slots naturally formed between adjacent teeth create discontinuities in magnetic flux, increasing the cogging torque and affecting motor efficiency. Simultaneously, the larger cogging torque affects the normal starting of brushless DC motors under low-voltage conditions. Furthermore, the limited stator slot width restricts the winding wire diameter; attempting to solve the problem of small wire diameter using multi-strand parallel winding inevitably increases the difficulty of winding.

[0003] Traditionally, adjacent sides of each phase winding with the same current direction are stacked vertically. During winding shaping, the upper and lower layers of enameled wire tend to intersect, making it difficult to shape to the same thickness as an adjacent side. Therefore, the inner diameter and roundness of the entire stator winding after rounding are difficult to control; consequently, the uniformity of the air gap between the rotor and stator is also difficult to guarantee. If two windings overlap at the ends, the coil end height will inevitably be higher, and the amount of copper used at the end will also increase. Increased coil end height also increases the overall length of the brushless coreless motor stator. Summary of the Invention

[0004] To address the aforementioned technical problem of difficulty in controlling stator windings, this utility model provides a stator lap winding for a brushless hollow cup motor stator structure.

[0005] The technical solution of this utility model is as follows: A stator lap winding for a brushless hollow cup motor stator structure includes a stator lap winding body made of self-adhesive enameled wire. Each phase winding of the stator lap winding includes a first winding wound in a clockwise direction and a second winding wound in a counterclockwise direction. The first winding is completed by starting the winding wire, and then the winding transitions to the second winding wound in the opposite direction through the winding wire, and finally ends at the tail wire of the winding.

[0006] After the stator lap winding is shaped by rolling, the adjacent sides of each phase winding with the same current direction are closely attached side by side. The ends of the stator lap winding have a two-layer overlapping mesh structure. The stator winding overlaps at the ends, and self-drying AB soft glue is applied at the position where the two layers overlap.

[0007] The stator lap winding body is provided with an expanding round claw on the inner side. The expanding round claw of the six-lobed stator opens to expand and round the inner diameter of the stator lap winding body.

[0008] The technical solution of this utility model features a novel structure and ingenious, simple design. The wire diameter of the stator lap winding body is not limited by the slot width, reducing the difficulty of the manufacturing process. The stator lap winding of the brushless coreless motor consists of a first winding wound clockwise and a second winding wound counterclockwise for each phase, ensuring that the current direction of adjacent windings in each phase is consistent. The adjacent windings of each phase are closely arranged, which helps control the inner diameter and roundness of the stator winding after rounding, thus ensuring a uniform air gap between the rotor and stator. The stator lap winding of the brushless coreless motor uses self-adhesive enameled wire. During the rounding of the stator lap winding, a constant current is applied to the self-adhesive enameled wire. After the self-adhesive enameled wire adheres to each other, the stator expansion and rounding claws are released. In this way, the stator winding does not need to be glued and heat-cured for shaping, which saves costs and improves production efficiency. It can also effectively control the springback of the stator winding after rounding, ensuring the inner diameter and roundness of the stator after rounding. The ends of the stator lap winding of the brushless hollow cup motor are two overlapping mesh structures. Since the ends of the windings and the adjacent windings can be staggered in space, one winding does not need to cross another winding. The length of the arc at the end of the winding can be greatly reduced, thereby saving the amount of copper used at the end of the winding. Attached Figure Description

[0009] Figure 2 , 3 This is a schematic diagram of the structure of this utility model; Figure 4 This is a schematic diagram of the structure of the stator of this utility model after the three-phase six-winding coils are overlapped into a mesh and flattened. Figure 5 This is a schematic diagram of the structure of the stacked winding flattening fixture of this utility model; Figure 1 , 6 This is a schematic diagram of the structure of the present invention, showing the lapped windings rolled into a circle and then inserted into the stator; Figure 7 This is a schematic diagram of the structure of the lap winding round clamp of this utility model. Detailed Implementation

[0010] The present invention will be further described below with reference to the accompanying drawings and embodiments. Example

[0011] like Figure 1 , 2 The stator lap winding structure of a brushless hollow cup motor shown in 3, 4, 5, 6, and 7 is a stator lap winding. The stator lap winding body 3 is a cylindrical hollow cup-shaped lap winding. The stator lap winding body 3 is made of self-adhesive enameled wire. Each phase winding of the stator lap winding body 3 includes a first winding 9 wound in a clockwise direction and a second winding 10 wound in a counterclockwise direction. The first winding 9 is completed by starting the winding wire 6, and then transitions to the second winding 10 wound in the opposite direction through the winding wire 8, and finally ends at the winding tail wire 7.

[0012] After the stator lap winding body 3 is rolled and shaped, the adjacent sides of each phase winding with the same current direction are closely attached side by side. The ends of the stator lap winding body 3 are two overlapping mesh structures. The stator lap winding body 3 overlaps at the ends, and self-drying AB soft glue 12 is applied at the position where the two layers overlap.

[0013] The stator lap winding body 3 is provided with an expanding round claw 15 on the inner side. The six-lobed stator expanding round claw 15 opens to expand and round the inner diameter of the stator lap winding 3.

[0014] In use, it includes a toothless and slotless annular stator lamination 1. Insulating paper 2 separates the stator lamination 1 from the stator winding body 3 on its inner wall. The stator lamination 1 has an annular structure, and its outer circular surface 4 and inner circular surface 5 are cylindrical. A modified toothless and slotless stator lamination is used as the carrier for the magnetic flux generated by the rotor permanent magnet. Self-adhesive enameled wire is wound into two continuous windings. The first winding is wound clockwise, and then the second winding is wound counterclockwise. After preparing the three-phase windings, the six windings are arranged equidistantly in the order of windings U1\V1\W1\U2\V2\W2, ensuring that adjacent sides of each phase winding have the same current direction and are tightly attached. The windings overlap at the ends. Self-drying AB soft adhesive is applied to the overlapping positions of the two layers, pressing the winding ends into a flat, overlapping mesh. After the adhesive dries, the flat, overlapping mesh windings are connected end to end and rolled into a cylindrical hollow cup-shaped winding, which is then inserted into the stator laminations that have been lined with insulating paper. The six-lobed stator expansion claws open, expanding and rounding the inner diameter of the stator winding. While the main body of the stator lamination winding is rounding, a constant current is applied to the self-adhesive enameled wires of the winding. After the self-adhesive enameled wires adhere to each other, the stator expansion claws are released, completing the stator assembly of the brushless hollow cup motor with lamination windings.

[0015] The double-layer stator assembly for a brushless hollow cup motor provided by this utility model includes: toothless and slotless stator laminations 1, insulating paper 2, and a stator winding body 3. The stator laminations 1 of the brushless hollow cup motor differ from other brushless motor stators in that both the outer circular surface 4 and the inner circular surface 5 of the stator laminations are cylindrical surfaces, and the inner circular surface 5 of the stator laminations 1 has neither teeth nor slots. The stator laminations 1 serve as the carrier for the magnetic flux generated by the permanent magnets of the rotor. The insulating paper 2 is longer than the stator lamination thickness, separating the stator winding body 3 from the stator laminations 1 and providing insulation.

[0016] This utility model provides a schematic diagram of a single-phase winding for a brushless hollow cup motor. Self-adhesive enameled wire is continuously wound into two windings of the same phase. Each phase winding includes a first winding 9 wound clockwise and a second winding 10 wound counterclockwise. The first winding 9 is completed starting from the winding start line 6, then transitions to the second winding 10 wound in the opposite direction via the winding pass line 8, and finally ends at the winding tail line 7. Figure 3 This is a three-dimensional diagram showing the single-phase pair of windings in a brushless coreless motor after they have been rolled into a coil: the winding pass 8 naturally transitions from the upper end of the first winding 9 to the second winding 10; in addition, the enameled wires of the adjacent pairs of windings of each phase are tightly attached together, and the current direction is the same.

[0017] This utility model provides a top view of the stator with three-phase six-winding coils stacked and flattened into a mesh. After preparing six windings (three pairs in total, three phases), they are sequentially hung on six positioning posts 11 in the order of windings U1\V1\W1\U2\V2\W2. The six windings are arranged equidistantly, ensuring that adjacent sides of each phase winding (Note: U1 and U2; V1 and V2; W1 and W2) have the same current direction and are tightly adjacent. The windings overlap at the ends, and self-drying AB soft adhesive 12 is applied at the overlapping positions of the two layers. The purpose of AB soft adhesive 12 is to fix the relative positions of the six stacked windings, ensuring that the six stacked windings maintain a relatively fixed position during the subsequent winding rolling process; in addition, AB soft adhesive 12 is a soft adhesive and can still be rolled after curing. Figure 7 This is a three-dimensional schematic diagram of a clamping fixture for flattening the lap windings of a brushless hollow cup motor. As per the above requirements, the lap windings of the brushless hollow cup motor are placed equidistantly and sequentially on the lower die pressing block 14. The upper die pressing block 13 moves downwards to press the ends of the windings into a flat, overlapping mesh.

[0018] This is a three-dimensional schematic diagram of the brushless hollow cup motor stator winding assembly being rolled into a circle and inserted into the stator. After the AB soft glue 12 dries, the flat, overlapping mesh brushless hollow cup motor stator winding assembly body 3 is connected end to end and rolled into a cylindrical hollow cup-shaped winding, which is then inserted into the stator lamination 1 where the insulating paper 2 has been placed. This is a schematic diagram of the brushless hollow cup motor winding assembly rounding fixture. The six-lobed stator expansion rounding claw 15 opens, expanding and rounding the inner diameter of the stator winding assembly body 3. While the stator winding assembly body 3 is rounding, a constant current is applied to the self-adhesive enameled wire of the winding (Note: The setting of the constant current and the energizing time need to be determined according to the wire diameter of the self-adhesive enameled wire and the number of turns of the winding). After the self-adhesive enameled wire adheres to each other, the stator expansion rounding claw 15 is released. Thus, the brushless hollow cup motor winding assembly stator assembly is completed.

[0019] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A stator lap winding for a brushless hollow cup motor stator structure, comprising a stator lap winding body (3), characterized in that: The stator lap winding body (3) is made of self-adhesive enameled wire. Each phase winding of the stator lap winding body (3) includes a first winding (9) wound in a clockwise direction and a second winding (10) wound in a counterclockwise direction. The first winding (9) is completed by starting the winding wire (6), and then transitions to the second winding (10) wound in the opposite direction through the winding passing wire (8), and finally ends at the winding tail wire (7).

2. The stator lap winding for a brushless hollow cup motor stator structure according to claim 1, characterized in that: After the stator lap winding body (3) is rolled and shaped, the adjacent sides of each phase winding with the same current direction are closely attached side by side. The end of the stator lap winding body (3) is a two-layer overlapping mesh structure. The stator lap winding body (3) overlaps at the end. At the position where the two layers overlap, self-drying AB soft glue (12) is applied.

3. The stator lap winding for a brushless hollow cup motor stator structure according to claim 1, characterized in that: The stator lap winding body (3) is provided with an expansion rounding claw (15) on the inner side. The expansion rounding claw (15) of the six-lobed stator opens to expand and round the inner diameter of the stator lap winding body (3).

Images