CN109888955B - High-power-density disc type motor winding structure and winding preparation method thereof - Google Patents
High-power-density disc type motor winding structure and winding preparation method thereof Download PDFInfo
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- CN109888955B CN109888955B CN201910173110.0A CN201910173110A CN109888955B CN 109888955 B CN109888955 B CN 109888955B CN 201910173110 A CN201910173110 A CN 201910173110A CN 109888955 B CN109888955 B CN 109888955B
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Abstract
The invention relates to a high-power-density disc type motor winding structure and a winding preparation method thereof. The motor winding structure comprises a plurality of coil winding parts with the same structure, wherein the coil winding parts are embedded into an iron core groove in a short-distance or full-distance mode or are independently directly molded as a coreless winding, each coil winding part is formed by winding a coil structure unfolding part punched or cut from a copper plate from left to right, the coil structure unfolding part is laid on a steel plate in a shape similar to a wavy line, an optimal winding radius is determined according to the number of winding turns, an optimal lead sectional area is determined according to the area of a lower wire groove of a motor, and an optimal effective length of a coil is determined according to the size of the inner diameter and the outer diameter. The invention has the advantages of higher groove filling rate, better air gap flatness and higher utilization rate of inner diameter gaps, and is very beneficial to the design and processing of high power density. The winding structure can provide a plurality of sets of modular coil components, and is convenient for manufacturing the motor, thereby reducing the manufacturing cost and reducing the occurrence rate of manufacturing errors.
Description
Technical Field
The invention relates to the field of preparation of windings and coil components, in particular to a high-power-density disc type motor winding structure and a winding preparation method thereof.
Background
The disc type rotating motor becomes an important trend in the development of the high-power-density motor at present due to the advantages of short axial size, compact structure, good heat dissipation condition and the like. Such as these, a disc-type rotating electrical machine is constituted by two parts, a stator and a rotor, both of which are in a disc-type structure, and an air gap therebetween is a plane perpendicular to a rotational axis of the electrical machine. The improvement of the slot filling factor and the coreless design of the motor winding are effective ways for improving the power density of the motor, but the adoption of the two modes can influence the flatness of the whole winding and further influence the uniformity of an air gap plane, so that the high power density and the high performance are both difficult to be considered in the aspects of the design and the processing of the motor. Particularly, the difference between the inner diameter and the outer diameter of the winding of the disc motor is large, so that the winding at the outer diameter is more idle, the winding arrangement space at the inner diameter is tense, so that the space of the end part is tense, each coil is arranged in a mutually overlapped way at the end part, and the risk of short circuit caused by the damage of an insulating layer exists, and similar problems exist in the design and the processing method of the flat copper wire forming winding disclosed in patent numbers CN108768033A and CN108015119A applied to the winding of the disc motor.
In addition, patent numbers CN101490933B and US2012/0217836a1 disclose a structural form of hairpin winding, in which U-shaped conductors are inserted into slots and then the ends are bent and welded. The winding can improve the slot filling rate and the integral rigidity, but the winding structure is influenced by the process and can only be used as a wave winding, and the tool head of the end part shaping part before welding is complex and has difficulty in automatic treatment. Particularly, for the occasion that the requirements of some motors on electromotive force and magnetomotive force are high, the pitch needs to be flexibly selected by adopting a lap winding mode, or the end needs to be shortened by a short-distance coil of the lap winding, the winding is difficult to deal with.
Disclosure of Invention
The invention aims to provide a high-power-density disc type motor winding structure and a winding preparation method thereof, which aim to solve the technical problems and adopt the following technical scheme for realizing the aim:
a high-power-density disc type motor winding structure comprises a plurality of coil winding parts with the same structure, wherein the coil winding parts are embedded into an iron core groove in a short-distance or full-moment mode or are independently directly molded as an iron-core-free winding, each coil winding part is formed by punching or linearly cutting a copper plate and winding a coil structure unfolding part from left to right, the coil structure unfolding part is flatly paved on a steel plate in a wavy line shape, an optimal winding radius is determined according to the number of winding turns, an optimal lead sectional area is determined according to the area of a lower wire groove of a motor, and an optimal coil effective length is determined according to the size of the inner diameter and the outer diameter.
Preferably, the coil structure development member is subjected to an insulating layer coating treatment in a planar development.
Preferably, the starting end side of the coil structure uncoiling member is wound several times from inside to outside in the winding direction to form the coil wound member.
Preferably, the outer edge of the coil winding member has a shape of any one of a circle, a rectangle with a chamfer, and an ellipse.
Preferably, after the coil winding members are arranged according to the design requirement, the starting end side and the tail end side of each adjacent coil winding member are electrically connected by welding using a connecting member, or the starting end side and the tail end side of each adjacent coil winding member are electrically connected by welding according to the actual requirement.
Preferably, the two coil sides of the coil winding member are arranged in the two slots in a state of being in an upper layer or a lower layer, and no overlapping phenomenon occurs.
The coil structure unfolding piece greatly reduces the complexity of the insulating film coating process due to the planar unfolding state. The whole coil is formed by winding a plane part, manual wire winding is not needed, and for a winding adopting a fixed intercept, the whole winding can be manufactured only by adopting two structural parts, so that the mechanization of coil manufacturing is realized, the production efficiency is improved, and the coil is particularly suitable for single-layer chain winding and single-layer or double-layer overlapping winding. According to the coil produced by the invention, because each coil winding part and the adjacent coil winding parts are welded by adopting the structural parts, the overlapping and crossing phenomena do not exist, and the possibility of insulation damage in the coil manufacturing process is greatly reduced. In addition, the coil winding part saves the end nose of the traditional molded flat copper wire, reduces copper consumption and coil leakage inductance, and improves the efficiency of the motor.
A winding preparation method of a high-power-density disc type motor winding structure comprises the following steps: winding a plurality of turns of the starting end side of the coil structure unfolding piece from inside to outside along the winding direction to form a coil winding piece; then embedding the coil winding part into the iron core slot in a short-distance or full-distance mode according to the scheme designed by the motor, and directly molding a winding without the iron core; in this case, the coil windings are electrically connected by welding by the connecting member, and according to the design, each adjacent coil winding may be connected to the end side of another coil winding by using the winding head on the start end side of one coil winding, and the winding head on the end side of the coil winding is connected to the start end side of another coil winding by the connecting member; alternatively, a winding head on the starting end side of one of the coil winding elements is connected to the starting end side of the other coil winding element, and a winding head on the end side of the coil winding element is connected to the end side of the other coil winding element by a connector.
Compared with the prior art, the invention has the following advantages: the invention provides a lap winding structure, which has the advantages of higher slot filling rate, better air gap flatness and higher utilization rate of inner diameter gaps, and is very beneficial to the design and processing of high power density. The winding structure can provide a plurality of sets of modular coil components, and is convenient for manufacturing the motor, thereby reducing the manufacturing cost and reducing the occurrence rate of manufacturing errors.
Drawings
FIG. 1 is a schematic structural diagram of a single layer chain winding embodiment according to the present invention;
FIG. 2 is a schematic view of a coil structure deployment member on a steel plate in accordance with the present invention;
FIG. 3 is a schematic view illustrating a sequence of forming a coil winding member according to the present invention (a, b, c represent different steps);
fig. 4 is a schematic view of the connection between the coil winding members in the present invention.
Fig. 5 is a schematic structural view of an embodiment of a double stacked winding according to the present invention.
Wherein 1, 1A, 1B are coil winding members, 2 is a coil structure unwinding member, 3 is a connecting member, 4 is a winding start end side, 4A is a winding end side, and 5 is a winding.
Detailed Description
The invention is explained in further detail below with reference to the figures and the specific embodiments.
Example 1
Fig. 1 is a schematic diagram of a single layer chain winding structure according to one embodiment of the present invention. The winding structure (5) may comprise a plurality of coil windings (1) and connections (3); generally, the windings are three-phase windings, such as U-phase, V-phase, and W-phase. The number of turns of each phase of winding is equal, the resistance is equal, and the spatial distribution is different by 120 degrees. When the windings are multiple sets or branches, the windings can be connected in parallel or in series.
In this embodiment, the number of phases is 3, the number of slots is 96, the number of poles is 16, and the number of slots per phase per pole is 2, and a single-layer cross chain winding connection mode is adopted. Each phase winding comprises 16 coil windings (1), and two effective sides of each coil winding (1) span 6 slots.
According to the result of the motor design, each coil winding is 5 turns of wire, and the area of each turn of wire is 4.8mm2Thus, a sheet having a thickness of 0.8mm and an area of 1m can be used2The copper plate (a part of the steel strip) is punched, as shown in fig. 2, 93 coil structure development pieces (2) can be obtained at most, and the utilization rate of the copper material can reach 73%. And the coil structure uncoiling piece (2) is coiled after the insulating coating process is finished to form the coil coiling piece (1).
In the manufacturing process of the coil winding member (1), specifically, as shown in fig. 3, the starting end side (4) of the coil structure development member (2) is wound from left to right, and 9 winding positions each have a preferred winding radius. Finally, the coil winding (1) shown in fig. 3(c) is formed through fig. 3(b), the coil winding (1) has two coil sides, each of which has 5 turns of the flat copper wire, the winding start side (4) and the winding end side (4A) of the coil winding (1) are two leading ends of the coil winding, and the coil cross-sectional areas are completely the same. The leading end side lead-out head (4) and the tail end side lead-out head (4A) of each phase of adjacent coil winding pieces (1, 1A, 1B) are welded according to the figure 4 by adopting a connector (3) for 96 lead-out heads of the three-phase 48 coil winding pieces, and 6 lead-out heads are reserved as the connecting lead-out heads of the three-phase winding to form the winding (5) in a transverse flat state.
In addition, the state of the upper layer and the lower layer of the two coil sides of the coil winding piece (1) is arranged in the two grooves, so that the overlapping phenomenon is avoided, the process of wire passing and wire jumping in the traditional coil winding process is omitted, the groove fullness rate is improved, and the possibility is provided for manufacturing the double-layer coil. The coil of the invention can be embedded into an iron core groove as the coil of an iron core motor, can also be directly used as the coil of a coreless motor, and is particularly suitable for a high-density disk type rotating motor with strong requirements on thinning.
Example 2
Figure 5 is a schematic diagram of a dual stacked winding structure according to one embodiment of the present invention. The winding structure may include a plurality of coil wound pieces (1) and a connection piece (3). Generally, the windings are three-phase windings, such as U-phase, V-phase, and W-phase. The number of turns of each phase of winding is equal, the resistance is equal, and the spatial distribution is different by 120 degrees. When the windings are multiple sets or branches, the windings can be connected in parallel or in series.
In this case, the number of phases is 3, the number of slots is 96, the number of poles is 16, and the number of slots per phase per pole is 2, and a connection mode of double-layer lap winding is adopted. Each phase winding comprises 32 coil windings (1), and two effective sides of each coil winding (1) span 6 slots.
The coil wound material (1) can be produced by punching a coil structure spread member (2) having a thickness of 0.8mm and an area of 1 square meter in a copper plate by the method shown in fig. 2 and by the method shown in fig. 3. Different from the embodiment 1, the proposal has 2 coil sides in each slot, the three-phase winding has 96 coil winding parts in total, 192 leading heads are welded by adopting a connecting piece (3), 6 leading heads are reserved as the connecting leading heads of the three-phase winding, and the winding (5) in a transverse flat state is formed.
The outer edge of the coil winding member is formed in a fan shape, but the shape may be circular, elliptical, or rectangular with a chamfer. The invention is not only suitable for coils embedded in iron cores, but also suitable for coreless coils.
The foregoing is a preferred embodiment of the present invention, and it will be apparent to those skilled in the art that variations, modifications, substitutions and alterations can be made in the embodiment without departing from the principles and spirit of the invention.
Claims (2)
1. A high-power-density disc type motor winding structure is characterized by comprising a plurality of coil winding parts (1) with the same structure, wherein the coil winding parts are embedded into an iron core groove in a short-distance or full-distance mode or are independently directly formed as a coreless winding, and each coil winding part (1) is formed by winding a coil structure unfolding part (2) punched or cut out from a copper plate from left to right;
determining an optimal wire section area according to the area of a lower wire slot of a motor, punching or linearly cutting a coil structure unfolding piece (2) on a copper plate, wherein the coil structure unfolding piece (2) is laid on a steel plate in a shape similar to a wavy line, the coil structure unfolding piece (2) is subjected to insulating layer coating treatment in a planar unfolding mode, an optimal winding radius is determined according to the number of winding turns, an optimal effective coil length is determined according to the size of an inner diameter and an outer diameter, a winding position is determined between the starting end side and the tail end side of the coil structure unfolding piece (2), the coil structure unfolding piece (2) is wound at the winding position according to the corresponding winding radius, and the coil structure unfolding piece (2) is wound from the starting end side to the winding direction from the inside to the outside for a plurality of turns to form a coil winding piece (1); the outer edge of the coil winding piece (1) is in any shape of a circle, a rectangle with a chamfer or an ellipse;
after the coil winding pieces (1) are arranged according to the design requirement, the starting end side and the tail end side of each adjacent coil winding piece (1) are electrically connected by welding through a connecting piece (3), or the starting end side and the starting end side of each adjacent coil winding piece (1) are electrically connected by welding according to the actual requirement; the two coil sides of the coil winding piece (1) are arranged in the two grooves in a state of being above and below the two coil sides, and the overlapping phenomenon is avoided.
2. A winding preparation method of a high power density disc type motor winding structure according to claim 1, characterized by comprising the following steps: determining a winding position between a starting end side and a tail end side of the coil structure unfolding piece (2), winding the coil structure unfolding piece (2) at the winding position according to a corresponding winding radius, and winding the coil structure unfolding piece (2) from the starting end side to the tail end side along a winding direction for a plurality of turns from inside to outside to form a coil winding piece (1); then embedding the coil winding piece (1) into the iron core slot in a short-distance or full-distance mode according to the scheme of motor design, and directly molding a winding without the iron core; in this case, the coil windings (1) are electrically connected by welding using the connecting piece (3), and according to the design, each adjacent coil winding (1) is connected to the end side of the other coil winding (1A) by using the winding head on the starting end side of one coil winding (1), and the winding head on the end side of the coil winding (1) is connected to the starting end side of the other coil winding (1B) by using the connecting piece (3); or the winding head at the starting end side of one coil winding piece (1) is connected with the starting end side of the other coil winding piece (1A), and the winding head at the tail end side of the coil winding piece (1) is connected with the tail end side of the other coil winding piece (1B) by a connector (3).
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201910173110.0A CN109888955B (en) | 2019-03-07 | 2019-03-07 | High-power-density disc type motor winding structure and winding preparation method thereof |
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| CN201910173110.0A CN109888955B (en) | 2019-03-07 | 2019-03-07 | High-power-density disc type motor winding structure and winding preparation method thereof |
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| CN109888955A CN109888955A (en) | 2019-06-14 |
| CN109888955B true CN109888955B (en) | 2022-05-17 |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| WO2021196523A1 (en) * | 2020-04-02 | 2021-10-07 | 苏卫星 | Combined electric motor |
| CN113517795A (en) * | 2021-09-07 | 2021-10-19 | 北京精雕科技集团有限公司 | Rotating electric machine |
Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH0955330A (en) * | 1995-08-14 | 1997-02-25 | Siemens Ag | Insulation method of molded wound coil |
| JP2008010743A (en) * | 2006-06-30 | 2008-01-17 | Hokkaido | Coil component, and its manufacturing method |
| JP2015173561A (en) * | 2014-03-12 | 2015-10-01 | 株式会社デンソー | Stator winding, method of manufacturing stator winding, stator, rotary electric machine, and wheel |
| JP2016052193A (en) * | 2014-08-29 | 2016-04-11 | 株式会社小松製作所 | Coil for motor, and motor |
| CN107078580A (en) * | 2014-09-18 | 2017-08-18 | 爱信艾达株式会社 | Stator |
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2019
- 2019-03-07 CN CN201910173110.0A patent/CN109888955B/en active Active
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH0955330A (en) * | 1995-08-14 | 1997-02-25 | Siemens Ag | Insulation method of molded wound coil |
| JP2008010743A (en) * | 2006-06-30 | 2008-01-17 | Hokkaido | Coil component, and its manufacturing method |
| JP2015173561A (en) * | 2014-03-12 | 2015-10-01 | 株式会社デンソー | Stator winding, method of manufacturing stator winding, stator, rotary electric machine, and wheel |
| JP2016052193A (en) * | 2014-08-29 | 2016-04-11 | 株式会社小松製作所 | Coil for motor, and motor |
| CN107078580A (en) * | 2014-09-18 | 2017-08-18 | 爱信艾达株式会社 | Stator |
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