Stator of a winding and welding integrated brushless permanent magnet motor

Abstract

The application provides a stacked winding type integrated brushless permanent magnet motor stator, and belongs to the technical field of brushless motors. The stacked winding type integrated brushless permanent magnet motor stator comprises a circumferential array of pole columns, an electric welding winding and a power generation winding. The pole columns are divided into two parts, namely single poles and multiple poles. The electric welding winding is wound on all the multiple poles first, and the power generation winding is wound on all the pole columns later. Two layers of windings are formed on the multiple poles, and a single layer of winding is formed on the single poles. The application has the following effects: the electric welding winding and the power generation winding adopt the single winding and stacked winding mode, the volume is reduced, the efficiency is improved, heat dissipation is facilitated, and winding parameters can be changed to adapt to various requirements.

Description

Technical Field

[0001] This application relates to the field of brushless motor technology, and more specifically, to the stator of a lap-wound and welded integrated brushless permanent magnet motor. Background Technology

[0002] In the portable small gasoline generator set industry, variable frequency generator sets are gaining an increasingly larger market share due to their advantages over conventional excitation generator sets of the same power, including smaller size, lighter weight, higher power quality, and greater functional expandability. Against this backdrop, a digital motor stator has emerged that integrates power generation and welding output into a single unit, enabling generator sets to perform both welding and power generation functions without increasing the number or size of the motors.

[0003] Currently available integrated generator and welding motors all have their generator windings and welding windings wound separately. Taking a conventional 27-pole motor stator as an example, to prioritize the welding output current, 18 poles are used for welding output, leaving only the remaining 9 poles for generator output. With a 40mm thick lamination core and a rotor using Y33 magnets, the generator output power can only reach 1.2KW, resulting in a power utilization rate of only 30%. If the motor also needs to provide an auxiliary winding output, one more generator winding pole needs to be removed to wind the auxiliary winding, further reducing the generator power. Because the welding and generator coils are not wound in a balanced manner, the magnetic reluctance generated by the motor during welding and generator operation is unbalanced, leading to uneven heating of the motor coils and severe generator vibration. Utility Model Content

[0004] To overcome the above deficiencies, this application provides a stator for a lap-wound integrated brushless permanent magnet motor, which aims to improve the problems mentioned in the background art.

[0005] This application provides a stator for a lap-wound integrated brushless permanent magnet motor, including a circumferential array of pole posts, an electric welding winding, and a power generation winding. The pole posts are divided into single poles and double poles. The electric welding winding is first wound on all the double poles, and the power generation winding is then wound on all the pole posts. Two layers of windings are formed on the double poles, and a single layer of windings is formed on the single poles.

[0006] In one specific implementation, there are a total of 27 poles, with 1-18 being bipolar and 19-27 being single-pole poles.

[0007] In one specific implementation, the welding winding uses a wire diameter of 1.5mm, and the two sets of welding windings are independently wound on poles 1-9 and 10-18 respectively, with 17 turns on each pole, wound clockwise and rotated counterclockwise, and connected in a delta configuration.

[0008] In one specific implementation, the power generation winding uses 0.7mm wire, with 80 turns for poles 19-27 and 16 turns for each pole 1-18, wound clockwise and rotated counterclockwise, connected in a star configuration. The power generation windings 1-18 are overlapped on the poles of the already wound welding winding, forming two layers of windings.

[0009] In the above implementation process, this application first introduces a 120A welding / 3.0KW generator lap-wound integrated welding and generator motor. Compared with conventional integrated welding and generator stators on the market, this utility model increases the wire diameter of the welding winding and reduces the number of turns, thereby widening the remaining distance between two adjacent poles without reducing the welding output current. This allows the generator winding to have sufficient space to be lapped on the poles already wound with copper wire. The generator winding is wound between the poles of the welding winding, thus expanding the generator winding of the entire stator and increasing the power. Testing shows that under the same speed conditions, this solution can achieve a generator power of 2.7~3.0KW, while conventional motors on the market can only achieve 1.0~1.4KW.

[0010] Meanwhile, by increasing the wire diameter of the welding winding and reducing the number of turns, this invention offers advantages such as a lower voltage drop ratio and lower winding resistance without reducing the welding output current. Tests show that, under the same rotational speed, when outputting a 120A welding current, the voltage drop of this invention is 54V under no-load and 24V under load, while a conventional integrated welding stator has 80V under no-load and 24V under load. The lower voltage drop results in a lower motor temperature rise and increases the motor's durability.

[0011] Conventional welded motor stators on the market use integrally stamped iron cores. The purpose of this is to generate a larger magnetic flux and thus increase power. However, this invention improves power through a new winding technology, so it uses a wound iron core with lower magnetic flux to balance costs.

[0012] In one specific implementation, there are a total of 27 poles, with 1-24 being bipolar and 25-27 being single-pole poles.

[0013] In one specific implementation, the welding winding uses a wire diameter of 1.4mm, and the two sets of welding windings are independently wound on poles 1-12 and 13-24 respectively, with 13 turns on each pole, wound clockwise and rotated counterclockwise, and connected in a delta configuration.

[0014] In one specific implementation, the power generation winding uses 0.5mm wire diameter, with 160 turns for poles 25-27, 1 turn for pole 1, and 20 turns for poles 2-23. The winding is clockwise, the poles are rotated counterclockwise, and the connection is in a star configuration. The power generation windings 1-23 are stacked on the pole post of the welding winding that has already been wound, forming two layers of windings.

[0015] In the above implementation process, this application further introduces a welding and generator integrated motor with a large market demand of 170A / 1.5KW lap-wound winding. Its two-layer winding technology is completely consistent with the above-mentioned welding and generator integrated motor with a 120A / 3.0KW lap-wound winding winding, only the winding parameters, namely the number of turns, wire diameter and winding position, are changed.

[0016] Compared with the prior art, the welding winding and power generation winding in this application adopt single winding and lap winding methods, which have the following advantages: 1. Reduced motor size and weight: By using two layers of winding, the volume of the permanent magnet motor is utilized as much as possible, reducing the size of the motor for the same power.

[0017] 2. Significantly improve efficiency: By adjusting the wire diameter, number of turns, or connection method, the two sets of windings can achieve phase complementarity, thereby increasing power density; optimizing the magnetic flux path and maximizing the utilization of the stator core's magnetic energy.

[0018] 3. Improved heat dissipation efficiency: The double-layer structure improves heat dissipation, reduces the temperature rise of the motor, and indirectly increases power.

[0019] 4. Flexible adaptation to diverse market demands: Welding power and power generation power can be arbitrarily combined and wound within the total rated power range of the motor according to customer requirements. Attached Figure Description

[0020] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of the winding method of the welding winding of the stator of the 120A welding / 3.0KW generator brushless permanent magnet motor with integrated welding and generating power provided in the embodiments of this application; Figure 2 A schematic diagram of the winding method of the generator winding of the stator of the 120A welding / 3.0KW generator integrated brushless permanent magnet motor provided in the embodiments of this application; Figure 3 A schematic diagram of the finished stator of a 120A / 3.0KW lap-wound integrated welding and generating brushless permanent magnet motor provided for the embodiments of this application; Figure 4 This is a schematic diagram of the winding method of the welding winding of the stator of the 170A welding / 1.5KW generator brushless permanent magnet motor with integrated welding and generating functions provided in the embodiments of this application. Figure 5 A schematic diagram of the winding method of the generator winding of the stator of the 170A welding / 1.5KW generator integrated brushless permanent magnet motor provided for the embodiments of this application; Figure 6 A schematic diagram of the finished stator of a 170A / 1.5KW lap-wound integrated welding and generating brushless permanent magnet motor provided for the embodiments of this application.

[0022] In the diagram: 100 - pole post; 200 - welding winding; 300 - generator winding. Detailed Implementation

[0023] The technical solutions in the embodiments of this application will now be described with reference to the accompanying drawings.

[0024] Please see Figures 1-6 This application provides a stator for a lap-wound integrated brushless permanent magnet motor, comprising a circular array of pole posts 100, an electric welding winding 200, and a generating winding 300. The pole posts 100 are divided into single-pole and multi-pole sections. The electric welding winding 200 is wound first on all multi-pole sections, and the generating winding 300 is then wound on all pole posts 100. Two layers of windings are formed on the multi-pole sections, and a single layer of winding is formed on the single-pole sections. The electric welding winding 200 and the generating winding 300 employ single-winding and lap-winding methods, reducing volume, improving efficiency, facilitating heat dissipation, and allowing for variable winding parameters to adapt to diverse needs.

[0025] Example 1 Please see Figures 1-3There are 27 pole posts 100 in total, with 1-18 being multi-pole and 19-27 being single-pole. The welding winding 200 uses 1.5mm wire diameter, and the two sets of welding windings 200 are independently wound on poles 1-9 and 10-18 respectively, with 17 turns per pole, wound clockwise and rotated counterclockwise, connected in a delta configuration. The generating winding 300 uses 0.7mm wire diameter, with 80 turns on poles 19-27 and 16 turns per pole on poles 1-18, wound clockwise and rotated counterclockwise, connected in a star configuration. The generating windings 300 on poles 1-18 are overlapped on the pole posts 100 already wound with welding windings 200, forming two layers of windings. This application first introduces a 120A welding / 3.0KW generator integrated stator with overlapping windings. Compared to conventional integrated welding stators on the market, this invention increases the wire diameter of the welding winding 200 and reduces the number of turns, thus widening the remaining distance between two adjacent poles 100 without reducing the welding output current. This allows the generator winding 300 sufficient space to overlap with the poles 100 already wound with copper wire. The generator winding 300 is wound between the poles 100 of the welding winding 200, thereby expanding the generator winding 300 of the entire stator and increasing the power. Testing shows that under the same speed conditions, this solution can achieve a generator power of 2.7~3.0KW, while conventional motors on the market can only achieve 1.0~1.4KW.

[0026] Meanwhile, by increasing the wire diameter of the welding winding 200 and reducing the number of turns, this invention achieves lower voltage drop and lower winding resistance without reducing the welding output current. Testing shows that, under the same rotational speed, when outputting a 120A welding current, the voltage drop of this invention is 54V under no-load and 24V under load, while a conventional integrated welding stator has 80V under no-load and 24V under load. The lower voltage drop results in lower motor temperature rise and increases motor durability.

[0027] Conventional welded motor stators on the market use integrally stamped iron cores. The purpose of this is to generate a larger magnetic flux and thus increase power. However, this invention improves power through a new winding technology, so it uses a wound iron core with lower magnetic flux to balance costs.

[0028] Example 2 Please see Figures 3-6There are 27 pole posts 100 in total, with 1-24 being multi-pole and 25-27 being single-pole. The welding winding 200 uses 1.4mm wire diameter, and the two sets of welding windings 200 are independently wound on poles 1-12 and 13-24 respectively, with 13 turns per pole. The winding is clockwise, and the poles are rotated counterclockwise, with a delta connection. The generating winding 300 uses 0.5mm wire diameter, with 160 turns on poles 25-27, 1 turn on pole 1, and 20 turns on poles 2-23. The winding is clockwise, and the poles are rotated counterclockwise, with a star connection. The generating windings 300 on poles 1-23 are overlapped on the pole posts 100 already wound with welding windings 200, forming two layers of windings. This application also introduces a welding-generating 170A / generating 1.5KW lap-wound integrated welding-generating motor with significant market demand. Its two-layer lap-wound technology is completely consistent with the aforementioned welding-generating 120A / generating 3.0KW lap-wound integrated welding-generating motor, with only the winding parameters—number of turns, wire diameter, and winding position—being changed.

[0029] The welding winding 200 and the generator winding 300 adopt single winding and lap winding methods, which have the following advantages: 1. Reduced motor size and weight: By using two layers of winding, the volume of the permanent magnet motor is utilized as much as possible, reducing the size of the motor for the same power.

[0030] 2. Significantly improve efficiency: By adjusting the wire diameter, number of turns, or connection method, the two sets of windings can achieve phase complementarity, thereby increasing power density; optimizing the magnetic flux path and maximizing the utilization of the stator core's magnetic energy.

[0031] 3. Improved heat dissipation efficiency: The double-layer structure improves heat dissipation, reduces the temperature rise of the motor, and indirectly increases power.

[0032] 4. Flexible adaptation to diverse market demands: Welding power and power generation power can be arbitrarily combined and wound within the total rated power range of the motor according to customer requirements.

[0033] In summary: The welding winding 200 and the generator winding 300 adopt single winding and lap winding methods, which reduces the size, improves efficiency, facilitates heat dissipation, and allows for variable winding parameters to meet diverse needs.

[0034] The above are merely embodiments of this application and are not intended to limit the scope of protection of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, improvements, or equivalent substitutions made within the spirit and principles of this application should be included within the scope of protection of this application. It should be noted that similar reference numerals and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

Claims

1. A stator for a lap-wound, welded, integrated brushless permanent magnet motor, characterized in that: It includes a circular array of pole posts (100), welding windings (200) and power generation windings (300). The pole posts (100) are divided into single poles and double poles. The welding windings (200) are first wound on all the double poles, and the power generation windings (300) are then wound on all the pole posts (100). Two layers of windings are formed on the double poles, and a single layer of windings is formed on the single poles.

2. The stator of the lap-wound integrated brushless permanent magnet motor according to claim 1, characterized in that, There are 27 poles (100) in total, with 1-18 being bipolar and 19-27 being single poles.

3. The stator of the lap-wound integrated brushless permanent magnet motor according to claim 2, characterized in that, The welding winding (200) uses a wire diameter of 1.5mm. The two sets of welding windings (200) are independently wound on poles 1-9 and 10-18 respectively, with 17 turns on each pole. The winding is clockwise and the poles are rotated counterclockwise. The wires are connected in a delta configuration.

4. The stator of the lap-wound integrated brushless permanent magnet motor according to claim 3, characterized in that, The power generation winding (300) uses 0.7mm wire diameter, with 80 turns for poles 19-27 and 16 turns for each pole 1-18. The winding is clockwise and the poles are rotated counterclockwise. The winding is connected in a star configuration. The poles 1-18 of the power generation winding (300) are stacked on the pole post (100) of the welding winding (200) to form two layers of winding.

5. The stator of the lap-wound integrated brushless permanent magnet motor according to claim 1, characterized in that, There are 27 poles (100) in total, with 1-24 being bipolar and 25-27 being single poles.

6. The stator of the lap-wound integrated brushless permanent magnet motor according to claim 5, characterized in that, The welding winding (200) uses a wire diameter of 1.4mm. The two sets of welding windings (200) are independently wound on poles 1-12 and 13-24 respectively, with 13 turns on each pole. The winding is clockwise and the poles are rotated counterclockwise. The wires are connected in a delta configuration.

7. The stator of the lap-wound integrated brushless permanent magnet motor according to claim 6, characterized in that, The power generation winding (300) uses 0.5mm wire diameter, with 160 turns for poles 25-27, 1 turn for pole 1, and 20 turns for poles 2-23. The winding is clockwise, the poles are rotated counterclockwise, and the connection is in a star configuration. The poles 1-23 of the power generation winding (300) are overlapped on the pole post (100) of the welding winding (200) to form two layers of winding.

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