Brushless motor and winding method for stator
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Solution Overview
Problem
The existing brushless motor stator core design with asymmetric pole teeth leads to non-uniform intervals, causing instability during magnet wire winding, resulting in reduced productivity and increased defects due to uneven tension and potential wire breakage.
Innovation Solution
The integration of auxiliary tooth tip sections on the stator core, formed using materials like resin, metal, or rubber, ensures uniform gaps between pole teeth, allowing for stable and uniform coil winding by fixing each tooth tip, thereby improving productivity and reducing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If asymmetric pole teeth are used to improve cogging torque, then holding torque is improved, but winding uniformity deteriorates
Solution Approach 1:
A guide core is introduced as an intermediary component during the winding process. The guide core has a circular cross-section that fits into the open slots of the pole teeth, providing a uniform reference surface for the flyer and magnet wire. This mediator compensates for the asymmetric shape of the pole teeth, ensuring uniform winding tension and preventing wire breakage while allowing the asymmetric pole teeth to maintain their cogging torque improvement benefits
Solution Approach 2:
The invention changes the geometric parameters of the winding machine components, specifically designing the guide core with a circular cross-section that matches the slot geometry. This parameter change creates a uniform interaction interface between the winding components and the pole teeth, transforming the variable tension condition into a uniform tension condition during the winding process
2Force
If asymmetric pole teeth are used to improve cogging torque, then holding torque is improved, but productivity deteriorates
Solution Approach 1:
The guide core acts as a mediator that enables high-speed winding by eliminating the instability caused by asymmetric pole teeth. By providing a uniform reference surface, the guide core prevents magnet wire breakage and eliminates the need to slow down the winding machine, thus maintaining high productivity while allowing the use of asymmetric pole teeth for improved holding torque
Solution Approach 2:
The guide core is pre-positioned in the open slots of the pole teeth before the winding process begins. This preliminary action ensures that the winding components interact with a uniform geometric reference from the start of the winding process, preventing tension variations and wire breakage that would otherwise require reduced winding speed
Data Source
AI summary
A brushless motor that can uniformly wind a coil winding at a low cost even with a stator core in which intervals between tooth tips of a plurality of pole teeth provided in a circumferential direction of an annular section to protrude in a radial direction differ. An auxiliary tooth tip section is formed integrally on a tooth tip of a required pole tooth of a stator core in which a plurality of pole teeth are provided in a circumferential direction of an annular section to protrude in a radial direction, and in which circumferential intervals between adjacent tooth tips are not uniform, and gaps between the tooth tips of all the pole teeth of the stator core are formed uniform.