BLDC Motor Winding Method for Vibration Reduction
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Solution Overview
Problem
Conventional DC motors with wave or lap winding methods experience significant vibration and noise due to uneven coil winding across core slots, leading to inconsistent brush contact and sequence issues.
Innovation Solution
A winding method for a BLDC motor that successively winds magnetic wires across core slots and adjacent slots over two pitches, including specific steps to manage U-phase, V-phase, W-phase, and GND windings, with a ground terminal between slots, to balance coil distribution and reduce copper wire volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional wave winding or lap winding methods are used in DC motors, then the winding process is relatively simple, but the coil distribution becomes uneven across core slots, causing significant vibration and noise during motor operation
Solution Approach 1:
The patent applies local quality by varying the winding configuration in different core slots. Specifically, the method winds coils in a first pattern for odd-numbered core slots and in a different pattern for even-numbered core slots, creating localized variations in coil distribution that balance the overall magnetic field and eliminate the unevenness causing vibration and noise.
2Ease of manufacture
If conventional winding methods are used, then the manufacturing process is straightforward, but the timings of brush contact with commutator segments become inconsistent, leading to sequence issues and performance degradation
Solution Approach 1:
The patent segments the winding process into distinct patterns for different core slots. By dividing the 12 core slots into odd-numbered and even-numbered groups and applying different winding sequences to each group, the method ensures that brush contact timings are standardized and consistent across all commutator segments, eliminating sequence issues.
3Ease of manufacture
If ground copper wire is not properly adjusted in BLDC motor winding, then the winding process is simpler, but automation cost and manufacturing time increase
Solution Approach 1:
The patent applies preliminary action by pre-planning and pre-positioning the ground copper wire during the winding process. The method specifically addresses ground wire routing in advance by winding coils in a predetermined pattern that naturally accommodates the ground wire path, eliminating the need for separate adjustment steps and reducing manufacturing time.
Data Source
AI summary
A winding method for a BLDC motor is disclosed. The winding method is configured to successively wind two magnetic wires across each core slot and its adjacent core slot (over two pitches) in a brushless direct current (BLDC) motor including a U-phase winding, a V-phase winding, a W-phase winding and a GND winding, 12 core slots, and a ground terminal. The winding method includes: a first step of moving and winding the magnetic wires; a second step of moving and winding the magnetic wires; a third step of moving and winding the magnetic wires; a fourth step of moving, winding, moving, and cutting the magnetic wires; a fifth step of moving and winding the magnetic wires; and a sixth step of moving the magnetic wires, passing the magnetic wires through an adjacent core slot and the ground terminal, and moving and cutting the magnetic wires.