CN113394894B - Winding structure of disc-type coreless permanent magnet motor and manufacturing method thereof - Google Patents

Abstract

The invention relates to a winding structure of a disk-type ironless permanent magnet motor and a manufacturing method thereof, wherein the winding structure includes three single-phase winding disks and side pressure plates, and the circumferential difference of the single-phase winding disks is 120 degrees in electrical angle along the axial direction. Stacked, three single-phase winding disks are fixedly connected, and the side pressure plate is installed on the top three-phase winding disk. Compared with the prior art, the invention has the advantages of high production and operation efficiency, simple manufacturing process, material saving, low manufacturing cost, high mechanical strength and good heat dissipation.

Description

Winding structure and manufacturing method of a disc-type ironless permanent magnet motor

technical field

The invention relates to the technical field of ironless permanent magnet motor manufacturing, in particular to a winding structure of a disc-type ironless permanent magnet motor and a manufacturing method thereof.

Background technique

At present, the disc-type coreless permanent magnet motor has a series of advantages such as high power/torque density, high efficiency, low torque fluctuation, and stable operation. The propulsion device system has been rapidly popularized and applied.

The existing disc-type coreless permanent magnet motor generally has surface-mounted permanent magnets on the circumference of the rotor. The permanent magnets use Halbach arrays to enhance the magnetic field in the motor and the sine degree of the air gap waveform. There is no iron core on the stator, only the winding and Non-magnetic, non-conductive insulating support material, so there is no torque ripple caused by cogging. There are two types of winding structures: wire-wound and printed circuit board (PCB). The wire-wound winding is used for large-capacity motors, while the printed circuit board type is used for small-capacity motors. The printed circuit board type has limited its application due to poor heat dissipation and poor mechanical strength. After the wire-wound winding is wound and shaped, it is filled with epoxy resin and positioned to form a winding disk. Both sides are packaged and reinforced with high-strength composite materials such as polyimide, carbon fiber, and ceramics.

The winding of the disc ironless permanent magnet motor is exposed to the environment of strong magnetic field. Due to the influence of skin effect and proximity effect, the AC resistance is large, the eddy current loss is large, the efficiency is reduced, and the heat dissipation is affected. Therefore, the wire-wound winding materials of disc motors generally have the following methods: multi-strand thin electromagnetic round wires are twisted, litz wires, flat copper wires or thin sheet copper materials. The winding is divided into multiple centralized independent coils in series and parallel according to the division of phase bands. The shape of each coil is divided into circular, fan-shaped or polygonal shapes. Compared with the distributed coil winding, the overlap and end size between the coils are reduced. Small and material-saving.

The use of multi-strand thin electromagnetic round wires stranded or litz wires to make windings reduces eddy current loss to a certain extent and improves efficiency, but the slot fullness rate decreases, the volume of the motor and the amount of permanent magnets increase, and the power/torque density decreases; Windings made of copper wire or thin sheet copper have low eddy current loss, high efficiency, and high slot fill rate, but the bending of the winding is easy to damage the insulation, especially at the end of the winding. According to the division of phase bands, multiple centralized independent coils are connected in series and parallel. There are many connecting lines between coils and coil groups, and the process is complicated. The size of the winding end is still large, the amount of materials is large, and the efficiency needs to be further improved. Epoxy resin has low thermal conductivity, poor structural strength, and is easy to deform in high-temperature environments. The winding discs that rely on epoxy resin potting and positioning have poor mechanical strength and lack sufficient support. Damage, affect the service life.

Contents of the invention

The object of the present invention is to provide a winding structure of a disc-type ironless permanent magnet motor with high operating efficiency, prolonging the service life of the motor, high mechanical strength, and good heat dissipation in order to overcome the above-mentioned defects in the prior art and its manufacturing method .

The purpose of the present invention can be achieved through the following technical solutions:

A winding structure of a disk-type ironless permanent magnet motor, the winding structure includes three single-phase winding disks and side pressure plates; the single-phase winding disks are stacked axially with a mutual difference of 120 degrees in electrical angle in the circumferential direction , three single-phase winding disks are fixedly connected; the side pressure plate is installed on the top three-phase winding disk.

Preferably, the single-phase winding disk includes a single-phase coil, a winding bracket and potting filler; the single-phase winding disk fixes the single-phase coil in the winding bracket through the potting filler.

More preferably, the single-phase coil is made of long strips of thin copper material and insulating paper alternately wound in parallel and continuously, the stacking direction is along the radial direction, the air-gap magnetic induction line cuts the narrow side of the winding, and the coils are adjacent to each other The average pitch of the two effective sides of the cutting magnetic field is a pole pitch, the effective side is wound along a radial line, the inner end or the outer end alternately surrounds, the side end and the straight line effective side have the same axial dimension, and they are all copper sheets Wide sides, and located in the same plane, each phase winding has only one terminal on the inner side and one terminal on the outer side in the radial direction.

More preferably, the winding bracket is provided with a positioning support boss; the number, shape and height of the positioning support boss are respectively the same as the number of poles, the shape and the height of the winding of the disc ironless permanent magnet motor. match.

More preferably, the potting filler is epoxy resin.

More preferably, both the winding bracket and the side pressure plate are made of composite materials with high strength and high thermal conductivity.

More preferably, the outer circumference of the winding bracket and the side pressure plate are respectively provided with threaded holes corresponding to each other; the winding bracket and the side pressure plate realize the integrated positioning and support of the winding structure through screw connection.

More preferably, the coils in the three single-phase winding disks are connected by strip-shaped thin copper materials and welded to form an interphase star connection.

More preferably, the star connection terminal is wrapped and insulated.

A manufacturing method for any one of the above winding structures, the manufacturing method comprising:

Step 1: Make the winding bracket, side plate and single-phase coil;

Step 2: Assemble the single-phase coil winding into the winding bracket, and rely on the supporting boss in the winding bracket for initial positioning;

Step 3: Use the potting filler to fill the gap between the single-phase coil winding and the positioning support boss to form an independent single-phase winding disk;

Step 4: The three single-phase winding disks are stacked axially with a circumferential difference of 120 degrees in electrical angle, and the three-phase windings are connected with thin sheet copper, and welded to form an interphase star connection;

Step 5: Wrap and insulate the star terminal;

Step 6: Place the side pressure plate on the side of the winding bracket with the support boss, and use screws to connect the three single-phase winding disks and the side pressure plate to complete the manufacture of the winding structure of the disc ironless permanent magnet motor.

Compared with the prior art, the present invention has the following beneficial effects:

1. High operating efficiency: The winding structure of the iron-core permanent magnet motor in the present invention uses a single coil to be continuously wound along the axial direction to form a formed winding, which reduces the size of the end and completely eliminates the connection between the coils. It does not need to be bent in three-dimensional space, which ensures the insulation quality, simplifies the manufacturing process, reduces the losses of the windings, improves the operating efficiency of the motor, and saves a lot of raw materials.

2. Prolonging the service life of the motor: The winding structure of the ironless permanent magnet motor in the present invention enhances the mechanical strength, positioning and heat dissipation of the winding, prolongs the service life and reliable operation of the motor.

3. High mechanical strength and good heat dissipation: The winding structure of the iron-core permanent magnet motor in the present invention adopts high-strength, high-thermal-conductivity insulating bosses and their brackets for positioning, the mechanical strength is enhanced, and the windings maintain reliable positioning during the operation of the motor. Heat dissipation is easy.

Description of drawings

Fig. 1 is the schematic diagram of the three-phase winding coil of ironless permanent magnet motor in the embodiment of the present invention;

2 is a schematic diagram of a partial structure of a single-phase winding disc in an embodiment of the present invention;

Fig. 3 is a schematic structural diagram of a single-phase coil in an embodiment of the present invention;

FIG. 4 is a schematic structural view of a coil in an embodiment of the present invention;

Fig. 5 is a schematic structural diagram of a winding support in an embodiment of the present invention;

Fig. 6 is a schematic structural view of a side pressure plate in an embodiment of the present invention;

Fig. 7 is a schematic structural view of a single-phase winding disk after potting in an embodiment of the present invention;

Fig. 8 is a structural schematic diagram of three single-phase winding discs stacked and made into a star connection in an embodiment of the present invention;

Fig. 9 is a schematic structural view of the star connection terminal after being bandaged and insulated in the embodiment of the present invention;

Fig. 10 is a schematic diagram of the overall structure of the winding structure in the embodiment of the present invention;

Fig. 11 is a schematic flowchart of a method for manufacturing a winding structure in an embodiment of the present invention.

The numbers in the figure indicate:

1. Single-phase winding disc, 2. Side pressure plate, 101. Single-phase coil, 102. Winding support, 103. Potting filler, 104. Positioning support boss.

Detailed ways

The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by persons of ordinary skill in the art without making creative efforts shall fall within the protection scope of the present invention.

A winding structure of a disk-type iron-coreless permanent magnet motor, the winding coil stacking method is shown in Figure 1, and its structure is shown in Figure 10, including three single-phase winding disks 1 and a side pressure plate 2, single-phase The winding disks 1 are stacked axially with a circumferential difference of 120 degrees in electrical angle, three single-phase winding disks 1 are fixedly connected, and the side pressure plate 2 is installed on the top three-phase winding disk.

The structure of the single-phase winding disc is shown in Figure 2, Figure 3, Figure 4, Figure 5 and Figure 7, including a single-phase coil 101, a winding support 102 and a potting filler 103, and the single-phase winding disc 1 passes through the potting filler 103 fixes the single-phase coil 101 in the winding support 102 .

The structure of the single-phase coil 101 is shown in Fig. 3 and Fig. 4. It is composed of long strips of thin copper material and insulating paper, which are alternately wound in parallel and continuously. Side, the average pitch of the two effective sides of the adjacent cutting magnetic field of the coil is a pole pitch, the effective side is wound along a radial straight line, the inner end or the outer end alternately surrounds, the side end and the straight line effective side have the same axial dimension, Both are the broad sides of the copper sheet and are located in the same plane, and each phase winding has only one terminal on the inner side and one terminal on the outer side in the radial direction.

The winding support 102 is provided with positioning support bosses 104, the number, shape and height of the positioning support bosses 104 are respectively matched with the number of poles of the disc-type ironless permanent magnet motor, the shape and height of the winding. The positioning support boss 104 is used to fill and position the winding in the circumferential direction and radial direction, so as to ensure that the effective side and end of the winding do not undergo large displacement and deformation under the action of electromagnetic force and thermal stress. The side of the bracket facing the air gap and the side pressure plate are planar.

The potting filler 103 selected in this embodiment is epoxy resin.

Both the winding support 102 and the side pressure plate 2 in this embodiment are made of composite materials with high strength and high thermal conductivity, such as polyimide, carbon fiber, ceramics and the like.

Threaded holes corresponding to each other are respectively provided on the outer circumference of the winding support 102 and the side pressure plate 2 , and the winding support 102 and the side pressure plate 2 realize the integrated positioning and support of the winding structure through screw connection.

This embodiment also relates to a manufacturing method for the above-mentioned winding structure, the process of which is shown in Figure 11, including:

Step 1: Make the winding bracket, side plate and single-phase coil;

Step 2: Assemble the single-phase coil winding into the winding bracket, and rely on the supporting boss in the winding bracket for initial positioning;

Step 3: As shown in Figure 7, use the potting filler to fill the gap between the single-phase coil winding and the positioning support boss to form an independent single-phase winding disk;

Step 4: As shown in Figure 8, the three single-phase winding disks are stacked axially with a circumferential difference of 120 degrees in electrical angle, and the three-phase windings are connected with thin sheet copper, and welded to form an interphase star connection;

Step 5: As shown in Figure 9, wrap and insulate the star terminal;

Step 6: Place the side pressure plate on the side of the winding bracket with the support boss, and use screws to connect the three single-phase winding disks and the side pressure plate to complete the manufacture of the winding structure of the disc ironless permanent magnet motor.

It should be pointed out that the outer rotor motors of the motors in Figures 1 to 10 are taken as examples, but those skilled in the art should know that if the motor is an inner rotor motor, the inner terminal is the star terminal of the three-phase winding, and the outer The terminal is the outgoing terminal; if it is an outer rotor motor, the outer terminal is the star terminal of the three-phase winding, and the inner terminal is the outgoing terminal. The manufacturing process is the same as that of the inner rotor motor.

The flake-shaped copper material in this embodiment is preferably cut from H59-1 brass strip, and insulating paper needs to be wound together when winding, as shown in Figure 4; MYFB-1, MYFB-2 type wrapping flat Copper wire can be wound without insulating paper.

The above technical solution uses a single coil to be continuously wound along the axial direction to form a formed winding, which reduces the size of the end and completely eliminates the connection between the coils. It does not need to be bent in three-dimensional space during winding, ensuring the insulation quality and simplifying the winding process. The manufacturing process is improved, and the loss of the winding is reduced; the winding adopts high-strength, high-thermal-conductivity insulating bosses and their brackets for positioning, the mechanical strength is enhanced, the windings maintain reliable positioning during the operation of the motor, and the heat dissipation is easy, prolonging the use of the motor Life, improve operating efficiency, enhance the mechanical strength, positioning and heat dissipation of the winding, prolong the service life and reliable operation of the motor, and promote the application of disc-type iron-core permanent magnet motors to applications where the installation space is limited and the power/torque density is urgently needed It has potential application value in the fields of navigation, aviation, electric vehicles, precision servo systems, and new energy power generation.

The above is only a specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any person familiar with the technical field can easily think of various equivalents within the technical scope disclosed in the present invention. Modifications or replacements shall all fall within the protection scope of the present invention. Therefore, the protection scope of the present invention should be based on the protection scope of the claims.

Claims (8)

1. The winding structure of a disc-type coreless permanent magnet motor is characterized by comprising three single-phase winding discs (1) and side pressing plates (2); the three single-phase winding disks (1) are stacked axially with the mutual difference of 120 degrees in the circumferential direction, and are fixedly connected; the side pressing plates (2) are arranged on the three-phase winding disc at the top; the single-phase winding disc (1) comprises a single-phase coil (101), a winding bracket (102) and potting filler (103); the single-phase winding disc (1) fixes the single-phase coil (101) in the winding bracket (102) through potting filler (103);

the single-phase coil (101) is formed by alternately and continuously winding strip-shaped sheet copper materials and insulating paper in parallel, the winding direction is along the radial direction, the narrow sides of the winding are cut by air gap magnetic induction lines, the average pitch of two effective sides of adjacent cutting magnetic fields of the coil is a polar distance, the effective sides are wound along radial straight lines, the end parts of the inner side or the outer side are wound alternately, the axial sizes of the side end parts and the effective sides of the straight lines are the same, the side end parts and the effective sides of the straight lines are both wide sides of the copper sheets and are positioned in the same plane, and each phase of the winding only has 1 wiring terminal which is positioned on the inner side and 1 wiring terminal which is positioned on the outer side in the radial direction.

2. The winding structure of a disc-type coreless permanent magnet motor according to claim 1, wherein the winding support (102) is provided with a positioning support boss (104); the number, the shape and the height of the positioning support bosses (104) are respectively matched with the pole number and the shape and the height of a winding of the disc-type coreless permanent magnet motor.

3. The winding structure of a disc-type coreless permanent magnet motor according to claim 1, wherein the potting filler (103) is epoxy resin.

4. The winding structure of a disc-type coreless permanent magnet motor according to claim 1, wherein the winding frame (102) and the side pressure plates (2) are made of a high-strength high-thermal-conductivity composite material.

5. The winding structure of a disc-type coreless permanent magnet motor according to claim 1, wherein the winding support (102) and the outer circumference of the side pressing plate (2) are respectively provided with threaded holes corresponding to each other in position; the winding support (102) and the side pressure plate (2) are in threaded connection to realize integrated positioning and supporting of a winding structure.

6. A winding structure of a disc type coreless permanent magnet motor according to claim 1, wherein the coils of the three single-phase winding discs (1) are connected by an elongated thin copper material and are welded to form alternate star connection terminals.

7. The winding structure of a disc-type coreless permanent magnet motor according to claim 6, wherein the star connection is wrapped and insulated.

8. A manufacturing method for a winding structure according to any one of claims 1 to 7, characterized in that the manufacturing method comprises:

step 1: manufacturing a winding support, a side pressing plate and a single-phase coil;

step 2: assembling a single-phase coil winding into a winding support, wherein the single-phase coil is formed by alternately and continuously winding strip-shaped sheet copper materials and insulating paper in parallel, the winding direction is along the radial direction, an air gap magnetic induction line cuts the narrow side of the winding, the average pitch of two effective sides of adjacent cutting magnetic fields of the coil is a polar distance, the effective sides are wound linearly along the radial direction, the inner side end or the outer side end is wound alternately, the axial sizes of the side end and the linear effective side are the same, the side ends and the linear effective side are both wide sides of the copper sheet and are positioned in the same plane, each phase of winding only has 1 wiring terminal positioned at the inner side and 1 wiring terminal positioned at the outer side along the radial direction, and the initial positioning is carried out by a supporting boss in the winding support;

and step 3: filling gaps between the single-phase coil winding and the positioning support bosses with potting fillers to form an independent single-phase winding disc;

and 4, step 4: three single-phase winding disks are stacked in the axial direction at the circumferential direction with the mutual difference of 120 degrees, and are connected with a three-phase winding by adopting a sheet-shaped copper material and welded to form an interphase star connection end;

and 5: binding and insulating the star connection end;

step 6: and (3) placing a side pressing plate on one side of the winding support with the supporting boss, and connecting the three single-phase winding discs and the side pressing plate by using screws to complete the manufacturing of the disc type coreless permanent magnet motor winding structure.

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