Guide Core Lamination for Uniform Brushless Motor Winding
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Solution Overview
Problem
The existing winding methods for brushless motors face challenges in uniform coil winding due to asymmetric tooth tips in stator cores, leading to reduced productivity and increased defective ratios, as the non-uniform spaces around pole teeth cause instability in magnet wire tension and winding speed.
Innovation Solution
A method involving a guide core with symmetric tooth tips is laminated with the stator core, ensuring uniform distances between adjacent tooth tips, allowing for efficient and uniform coil winding even in cores with non-uniform tooth tip distances, using a wire winding machine that clamps and positions the guide core to maintain consistent clearance for uniform magnet wire introduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the stator core is designed with asymmetric tooth tips to improve cogging torque, then the holding torque is improved, but the spaces around pole teeth become nonuniform causing wire winding instability and reduced productivity
Solution Approach 1:
A guide core is introduced as an intermediary component between the asymmetric stator core and the winding machine. The guide core has symmetric tooth tips that provide uniform spaces, acting as a mediator that enables stable wire winding while allowing the stator core to maintain its asymmetric design for improved holding torque.
Solution Approach 2:
The stator core is segmented into two functional parts: the asymmetric pole teeth structure that provides improved holding torque, and the symmetric guide core that provides uniform winding spaces. This segmentation allows each part to fulfill its specific function without compromising the other.
2Force
If the stator core uses asymmetric tooth tips to increase holding torque, then the magnetic circuit performance is improved, but the nonuniform spaces cause magnet wire tension instability and increased defective ratio
Solution Approach 1:
The guide core serves as a mediator that interfaces between the asymmetric stator core and the winding process. Its symmetric tooth tips create uniform spaces that stabilize magnet wire tension during winding, preventing defects while the asymmetric stator core maintains its superior holding torque characteristics.
3Productivity
If the winding machine operates at high speed to improve productivity, then the output increases, but the nonuniform spaces around asymmetric tooth tips cause wire break due to increased tension
Solution Approach 1:
The guide core with symmetric tooth tips acts as a mediator that ensures uniform wire path and stable tension during high-speed winding. This allows the winding machine to operate at high speeds without causing wire break, as the guide core compensates for the nonuniform spaces created by the asymmetric stator core.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables uniform coil formation around pole teeth, improving productivity and reducing defective ratios by stabilizing the winding process and maintaining motor characteristics, even in stator cores with varying tooth tip distances.
Implementation Method 1
a guide core (14) is laminated with the stator core (4), the guide core having a plurality of pole teeth (14a) provided with tooth tips symmetric with respect to shaft lines in a radial direction, a distance between the adjacent tooth tips being uniform
Implementation Method 2
using a wire winding machine that clamps and positions the guide core to maintain consistent clearance for uniform magnet wire introduction
Implementation Method 3
winding the magnet wire around the pole tooth by rotating a flyer for holding a nozzle
Implementation Method 4
the magnet wire may not be wound uniformly around the pole tooth and a defect such as a wire break due to increase in the tension of the magnet wire may be caused
Data Source
AI summary
To provide a brushless motor in which a coil winding can be wound uniformly even when there is a difference in the distance between tooth tips of a plurality of pole teeth disposed in the circumferential direction of an annular part of a stator core so as to project in the radial direction. A guide core in which the distance between adjacent tooth tips of pole teeth is uniform and the tooth tips are symmetric with respect to the shaft lines in the radial direction is laminated integrally with a stator core in which a plurality of pole teeth is disposed in the circumferential direction of an annular part so as to project in the radial direction, and the distance in the circumferential direction between adjacent tooth tips is not uniform.