CN102255403B - Manufacturing process of brushless motor with iron-core-free disc winding and axial magnetic field - Google Patents
Manufacturing process of brushless motor with iron-core-free disc winding and axial magnetic field Download PDFInfo
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- CN102255403B CN102255403B CN 201110200376 CN201110200376A CN102255403B CN 102255403 B CN102255403 B CN 102255403B CN 201110200376 CN201110200376 CN 201110200376 CN 201110200376 A CN201110200376 A CN 201110200376A CN 102255403 B CN102255403 B CN 102255403B
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Abstract
The invention is suitable for the field of motors and provides a process for manufacturing a brushless motor with an iron-core-free disc winding and an axial magnetic field. The process includes steps of: firstly making wires into coils followed by annularly arranging a plurality of coils into a stator winding, then pressing and shaping the stator winding, further injection molding, covering a plastic layer on a surface of the winding and shaping stator through holes, simultaneously sleeving a hollow shaft in the stator through holes and welding a power line in a reserved weld leg of the stator winding along the hollow shaft, further annularly arranging a magnet on inner walls of a front end cover and a rear end cover, then respectively fixing a front end cover bearing and a rear end cover bearing in the through holes of the front end cover and the rear end cover, finally respectively passing two ends of the hollow haft through the front end cover bearing and the rear end cover bearing. The manufacturing process has the advantages of simple flow, easiness for operation and high production efficiency, and no iron core is arranged in the stator assembly of the manufactured brushless motor.
Description
Technical field
The invention belongs to machine field, relate in particular to a kind of manufacturing process of coreless disk winding axial magnetic field brushless motor.
Background technology
At present, conventional brushless electric machine all adopts the riveting of punching out silicon steel sheet stack to become motor stator and rotor iron core, then copper cash is around in the electromagnetic structure that consists of motor in the iron core teeth groove, adopt the brushless electric machine of this structure, because the magnetic field of motor is radial magnetic field, whole magnetic loop is longer, produce the alternation magnetic circuit during electric machine rotation in the iron core, cause iron core generation magnetic hysteresis and eddy current loss and then affect electric efficiency, and owing to the teeth groove that has iron core produces the cogging torque fluctuation, make motor can not satisfy the instructions for use in some precision instrumentation field.
Summary of the invention
The object of the present invention is to provide a kind of manufacturing process of coreless disk winding axial magnetic field brushless motor.
The invention provides a kind of manufacturing process of coreless disk winding axial magnetic field brushless motor, comprise the steps:
(1) wire is turned to default coil shape;
(2) a plurality of coils are connected from beginning to end, assembled arrangement circularizes, and makes stator winding;
(3) stator winding is sent in the mould compressing;
(4) again the stator winding after compressing is sent into injection mo(u)lding in the injection mold, a plastic layer on the whole surface coverage of stator winding, and mold the stator through hole at the stator winding center;
(5) hollow shaft is inserted in the stator through hole after the injection mo(u)lding, makes hollow shaft and stator through hole tight fit;
(6) endoporus of power line from hollow shaft penetrated, and pass from the side opening of hollow shaft, then be welded on the leg that the stator winding after the injection mo(u)lding reserves;
(7) magnet is individually fixed in the inwall of front end housing and rear end cap by the annular array mode;
(8) the front end housing bearing is fixedly arranged in the front end housing through hole on the front end housing, bearing of rear end cover is fixedly arranged in the rear end cap through hole on the rear end cap;
(9) two ends with hollow shaft are arranged in respectively on front end housing bearing and the bearing of rear end cover.
Manufacturing process of the present invention, simple, the easily operation of flow process, production efficiency is high, the stator module iron-core-free of the brushless electric machine of making has thoroughly been eliminated the fluctuation of core loss and cogging torque, and adopts axial magnetic field to reduce magnetic loop length, thereby reduce the magnetic circuit loss, improve the magnetic stock utilization, integral body has improved the efficient of motor, has enlarged the application of product.
Description of drawings
Fig. 1 is the cutaway view of the coreless disk winding axial magnetic field brushless motor that provides of the embodiment of the invention;
Fig. 2 is the schematic diagram of the coil that provides of the embodiment of the invention;
Fig. 3 is the schematic diagram of the stator winding that provides of the embodiment of the invention;
Fig. 4 is the schematic diagram of the magnet that provides of the embodiment of the invention;
Fig. 5 is that the magnet ring that provides of the embodiment of the invention is around the schematic diagram that is fixedly arranged on the front end housing;
Fig. 6 is that the magnet ring that provides of the embodiment of the invention is around the schematic diagram that is fixedly arranged on the rear end cap.
Embodiment
In order to make purpose of the present invention, technical scheme and advantage clearer, below in conjunction with drawings and Examples, the present invention is further elaborated.Should be appreciated that specific embodiment described herein only in order to explain the present invention, is not intended to limit the present invention.
Consult Fig. 1, a kind of coreless disk winding axial magnetic field brushless motor that the embodiment of the invention provides comprises stator module and rotor assembly, wherein,
Described stator module comprises stator winding 1, hollow shaft 2, power line 3, stator winding 1 and hollow shaft 2 are vertical to be arranged and is fixedly arranged on the hollow shaft 2, power line 3 is connected with external power source, power line 3 penetrates and passes from the side opening 22 of hollow shaft 2 from the endoporus 21 of hollow shaft 2, and the power line 3 after passing is electrically connected on the stator winding 1;
Described rotor assembly comprises front end housing 4, rear end cap 5, magnet 6, front end housing 4 and rear end cap 5 secure fit, and magnet 6 is fixedly arranged on respectively the inwall of front end housing 4 and rear end cap 5 and is oppositely arranged with stator winding 1;
Described front end housing 4 and rear end cap 5 are sheathed on respectively on the hollow shaft 2 and are rotationally connected;
Be provided with the gap between described stator winding 1 and the magnet 6, thereby so that whole rotor assembly can freely rotate with respect to stator module.In this area, the gap between stator winding 1 and the magnet 6 is commonly referred to air gap, and it is the path in magnetic field, is the path of power conversion, can cause the variation of magnetic circuit and magnetic resistance, and air gap is 0.2～0.5mm generally speaking.
During brushless electric machine work provided by the invention, at first the hollow shaft 2 with motor is fixed on the exterior support frame, and power line 3 connected driving power, the energising rear motor is namely started working, electric current is transported on the stator winding 1 from power line 3, according to electromagnetic induction principle, stator winding 1 after the energising produces axial magnetic field, magnetic force vertically penetrates the magnet 6 that is fixed on front end housing 4 and the rear end cap 5, make magnet 6 stressed, drive front end housing 4 and rear end cap 5 rotations, thereby whole rotor assembly is rotated around hollow shaft 2, reach the purpose of power stage.
Compare with the brushless electric machine of routine, stator module iron-core-free of the present invention has been avoided the iron core that adopts silicon steel sheet to make, and has thoroughly eliminated magnetic hysteresis and the eddy current loss of using iron core to produce, has improved the efficient of product; Stator module iron-core-free of the present invention, also the iron-core-free teeth groove has thoroughly been eliminated the unavoidable cogging torque fluctuation of conventional iron core motor, so that motor rotation is more level and smooth, be particularly suitable for the low speed smoothness run, conventional iron core motor low cruise is beated obviously even stuck phenomenon may be occurred; The present invention changes the radial magnetic field of routine and is designed to axial magnetic field, has shortened magnetic loop length, has also reduced the magnetic loss that produces in this magnetic loop, has improved the magnetic stock utilization.Therefore, the brushless electric machine of the alternative routine of the present invention, relatively more energy-conservation, and can enlarge application, and especially can satisfy the instructions for use in some precision instrumentation field, market prospects are very wide.
As shown in Figures 2 and 3, in the present embodiment, stator winding 1 is ring-type, by a plurality of coils 11 by the electromagnetic field order head and the tail of appointment connect, around forming; The shapes such as being shaped as of single coil 11 is fan-shaped, circle or polygon.
Such as Fig. 4, Fig. 5 and shown in Figure 6, in the present embodiment, a plurality of magnet 6 circularize in the inwall assembled arrangement of front end housing 4 and rear end cap 5 respectively, and the center of circle take the central point of front end housing 4 and rear end cap 5 as annular array.The shapes such as being shaped as of single magnet 6 is fan-shaped, circle or polygon.
As shown in Figure 1, in the present embodiment, the mode that is rotationally connected between front end housing 4 and the hollow shaft 2 is: offer axial forward end lid through hole 41 on the front end housing 4, be installed with a front end housing bearing 42 in the front end housing through hole 41, hollow shaft 2 is arranged on the front end housing bearing 42, thus the purpose that is rotationally connected between realization front end housing 4 and the hollow shaft 2.
As shown in Figure 1, in the present embodiment, the mode that is rotationally connected between rear end cap 5 and the hollow shaft 2 is: offer axial rearward end lid through hole 51 on the rear end cap 5, be installed with a bearing of rear end cover 52 in the rear end cap through hole 51, hollow shaft 2 is arranged on the bearing of rear end cover 52, thus the purpose that is rotationally connected between realization rear end cap 5 and the hollow shaft 2.
As shown in Figure 1, in the present embodiment, the mode that is fixedly connected with between front end housing 4 and the rear end cap 5 is: the edge of front end housing 4 and rear end cap 5 respectively correspondence offers a plurality of screw holes 43,53, and front end housing 4 and rear end cap 5 achieve a fixed connection by a plurality of screws 7 that are arranged in the screw hole 43,53.
As shown in Figure 1, in the present embodiment, the electric connection mode between power line 3 and the stator winding 1 is: power line 3 is welded on the reservation leg (not shown) of stator winding 1.
Such as Fig. 1～shown in Figure 6, the invention provides a kind of manufacturing process of coreless disk winding axial magnetic field brushless motor, comprise the steps:
(1) wire is turned to default coil shape, coil 11 can be the shapes such as fan-shaped, circle or polygon;
(2) electromagnetic field order head and the tail connection, the assembled arrangement of a plurality of coils 11 by appointment circularized, make stator winding 1;
(3) send in the mould stator winding 1 compressing;
(4) again the stator winding 1 after compressing is sent into injection mo(u)lding in the injection mold, a plastic layer on stator winding 1 whole surface coverage, and mold stator through hole 12 at stator winding 1 center, by coil 11 being made into stator winding 1 and its injection moulding being reinforced, make it not only sturdy and durable, and coil 11 frictions during operation, the operation noise is lower;
(5) hollow shaft 2 is inserted in the stator through hole 12 after the injection mo(u)lding, makes hollow shaft 2 and stator through hole 12 tight fits;
(6) endoporus 21 of power line 3 from hollow shaft 2 penetrated, and pass from the side opening 22 of hollow shaft 2, then be welded on the leg that the stator winding 1 after the injection mo(u)lding reserves, realize the purpose that power line 3 and stator winding 1 are electrically connected;
(7) magnet 6 is individually fixed in the inwall of front end housing 4 and rear end cap 5 by the annular array mode, and the center of circle take the central point of front end housing 4 and rear end cap 5 as annular array;
(8) front end housing bearing 42 is fixedly arranged in the front end housing through hole 41 on the front end housing 4, bearing of rear end cover 52 is fixedly arranged in the rear end cap through hole 51 on the rear end cap 5;
(9) two ends with hollow shaft 2 are arranged in respectively on front end housing bearing 42 and the bearing of rear end cover 52, thereby so that hollow shaft 2 is rotationally connected with front end housing 4 and rear end cap 5 respectively, and then finish the manufacture process of whole motor.
Manufacturing process of the present invention, simple, the easily operation of flow process, production efficiency is high, the stator module iron-core-free of the brushless electric machine of making has thoroughly been eliminated the fluctuation of core loss and cogging torque, and adopts axial magnetic field to reduce magnetic loop length, thereby reduce the magnetic circuit loss, improve the magnetic stock utilization, integral body has improved the efficient of motor, has enlarged the application of product.
The above only is preferred embodiment of the present invention, not in order to limiting the present invention, all any modifications of doing within the spirit and principles in the present invention, is equal to and replaces and improvement etc., all should be included within protection scope of the present invention.
Claims (1)
1. the manufacturing process of a coreless disk winding axial magnetic field brushless motor is characterized in that comprising the steps:
(1) wire is turned to default coil shape;
(2) a plurality of coils are connected from beginning to end, assembled arrangement circularizes, and makes stator winding;
(3) stator winding is sent in the mould compressing;
(4) again the stator winding after compressing is sent into injection mo(u)lding in the injection mold, a plastic layer on the whole surface coverage of stator winding, and mold the stator through hole at the stator winding center;
(5) hollow shaft is inserted in the stator through hole after the injection mo(u)lding, makes hollow shaft and stator through hole tight fit;
(6) endoporus of power line from hollow shaft penetrated, and pass from the side opening of hollow shaft, then be welded on the leg that the stator winding after the injection mo(u)lding reserves;
(7) magnet is individually fixed in the inwall of front end housing and rear end cap by the annular array mode;
(8) the front end housing bearing is fixedly arranged in the front end housing through hole on the front end housing, bearing of rear end cover is fixedly arranged in the rear end cap through hole on the rear end cap;
(9) two ends with hollow shaft are arranged in respectively on front end housing bearing and the bearing of rear end cover.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN 201110200376 CN102255403B (en) | 2011-07-18 | 2011-07-18 | Manufacturing process of brushless motor with iron-core-free disc winding and axial magnetic field |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN 201110200376 CN102255403B (en) | 2011-07-18 | 2011-07-18 | Manufacturing process of brushless motor with iron-core-free disc winding and axial magnetic field |
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| Publication Number | Publication Date |
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| CN102255403A CN102255403A (en) | 2011-11-23 |
| CN102255403B true CN102255403B (en) | 2013-04-17 |
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| Application Number | Title | Priority Date | Filing Date |
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| CN 201110200376 Active CN102255403B (en) | 2011-07-18 | 2011-07-18 | Manufacturing process of brushless motor with iron-core-free disc winding and axial magnetic field |
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Families Citing this family (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103280910B (en) * | 2013-04-23 | 2015-06-17 | 北京理工大学 | Magnetoelectric micro electric generator of axial magnetic field |
| CN105305742A (en) * | 2014-07-10 | 2016-02-03 | 山东省明康安托山特种机电有限公司 | Coreless motor stator winding forming machine constructing method and structure |
| JP6318945B2 (en) * | 2014-07-24 | 2018-05-09 | 株式会社安川電機 | Coreless linear motor armature, coreless linear motor, and manufacturing method of coreless linear motor armature |
| CN206585399U (en) * | 2016-07-25 | 2017-10-24 | 台达电子工业股份有限公司 | Mini-fan |
| CN108933506B (en) * | 2017-05-26 | 2019-09-20 | 大族激光科技产业集团股份有限公司 | A kind of coil windings apparatus for shaping applied to U-shaped linear motor |
| CN113765258B (en) * | 2021-08-18 | 2023-10-13 | 上海大学 | Composite multidirectional coreless disc motor |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN2412788Y (en) * | 2000-02-22 | 2001-01-03 | 张士秀 | Brushless DC motor for vehicle |
| CN201118413Y (en) * | 2007-10-29 | 2008-09-17 | 深圳航天科技创新研究院 | Disk three-phase brushless permanent magnetic DC electromotor |
| CN202167901U (en) * | 2011-07-18 | 2012-03-14 | 深圳市双环全新机电股份有限公司 | Coreless disk winding axial magnetic field brushless motor |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2009095070A (en) * | 2007-10-03 | 2009-04-30 | Mitsubishi Electric Corp | Rotary electric motor |
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Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN2412788Y (en) * | 2000-02-22 | 2001-01-03 | 张士秀 | Brushless DC motor for vehicle |
| CN201118413Y (en) * | 2007-10-29 | 2008-09-17 | 深圳航天科技创新研究院 | Disk three-phase brushless permanent magnetic DC electromotor |
| CN202167901U (en) * | 2011-07-18 | 2012-03-14 | 深圳市双环全新机电股份有限公司 | Coreless disk winding axial magnetic field brushless motor |
Non-Patent Citations (1)
| Title |
|---|
| JP特开2009-95070A 2009.04.30 |
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