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

Winding structure of disc-type coreless permanent magnet motor and manufacturing method thereof Download PDF

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CN113394894B
CN113394894B CN202110733690.1A CN202110733690A CN113394894B CN 113394894 B CN113394894 B CN 113394894B CN 202110733690 A CN202110733690 A CN 202110733690A CN 113394894 B CN113394894 B CN 113394894B
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winding
phase
disc
permanent magnet
magnet motor
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CN113394894A (en
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王爱元
姚晓东
张海燕
张超
李子金
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Foshan Gaoming Mingge New Electrical Control Research Institute
Shanghai Dianji University
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Foshan Gaoming Mingge New Electrical Control Research Institute
Shanghai Dianji University
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    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K3/00Details of windings
    • H02K3/04Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K15/00Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/04Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
    • H02K15/043Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines winding flat conductive wires or sheets
    • H02K15/0431Concentrated windings
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K15/00Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/04Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
    • H02K15/043Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines winding flat conductive wires or sheets
    • H02K15/0432Distributed windings
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K3/00Details of windings
    • H02K3/04Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/28Layout of windings or of connections between windings
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K3/00Details of windings
    • H02K3/46Fastening of windings on the stator or rotor structure
    • H02K3/47Air-gap windings, i.e. iron-free windings
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K2203/00Specific aspects not provided for in the other groups of this subclass relating to the windings
    • H02K2203/12Machines characterised by the bobbins for supporting the windings

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  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

本发明涉及一种盘式无铁芯永磁电机的绕组结构及其制造方法,其中绕组结构包括三个单相绕组盘和侧压板,单相绕组盘周向互差120度电角度沿轴向叠放,三个单相绕组盘固定连接,侧压板安装在顶部的三相绕组盘上。与现有技术相比,本发明具有生产和运行效率高、制造工艺简单、省材料、制造成本低、机械强度高、散热性好等优点。

Figure 202110733690

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.

Figure 202110733690

Description

一种盘式无铁芯永磁电机的绕组结构及其制造方法Winding structure and manufacturing method of a disc-type ironless permanent magnet motor

技术领域technical field

本发明涉及无铁芯永磁电机制造技术领域,尤其是涉及一种盘式无铁芯永磁电机的绕组结构及其制造方法。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.

背景技术Background technique

目前,盘式无铁芯永磁电机具有高功率/转矩密度、高效率、低转矩波动、运行平稳等一些列优势,在直驱发电系统、飞轮蓄能、高精度伺服系统、全电推进装置系统等得到了快速的推广应用。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.

现有的盘式无铁芯永磁电机一般转子周向上为表贴式永磁体,永磁体采用Halbach阵列,以增强电机内的磁场和气隙波形的正弦度,定子上无铁芯,只有绕组和不导磁、不导电的绝缘支撑材料,因此不存在齿槽效应引起的转矩波动。有绕线式和印刷电路板式(PCB)两种绕组结构型式,绕线式绕组用于大容量电机,而印刷电路板式用于小容量电机。印刷电路板式因散热差、机械强度差限制了其应用。绕线式绕组绕制成型后,灌注环氧树脂定位制成绕组盘,两侧采用高强度的复合材料如聚酰亚胺、碳纤维、陶瓷等封装加固支撑。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.

盘式无铁芯永磁电机的绕组暴露于强磁场的环境中,由于趋肤效应和邻近效应的影响,交流电阻大,涡流损耗大,效率下降,并影响散热。因此盘式电机绕线式绕组材料一般有以下几种方式:多股细电磁圆导线绞合、利兹线、扁铜线或薄片状铜材制成。绕组根据相带划分采用多个集中式独立线圈通过串并联构成,每个线圈的形状分为圆形、扇形或多边形等形状,相对于分布线圈绕组减少了线圈之间的交叠、端部尺寸小、省材料。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.

采用多股细电磁圆导线绞合或利兹线绕制绕组一定程度上降低了涡流损耗提高了效率,但槽满率降低,电机体积和永磁体用量增大,功率/转矩密度下降;采用扁铜线或薄片状铜材绕制绕组涡流损耗小、效率高、槽满率高,但绕组弯折处容易损坏绝缘,尤其是绕组端部。根据相带划分采用多个集中式独立线圈通过串并联构成,存在线圈及线圈组之间的连接线多、工艺复杂的问题,绕组端部尺寸依然较大,材料用量大,效率有待进一步提升。环氧树脂导热系数低、结构强度差、高温环境下容易变形,依靠环氧树脂灌封定位的绕组盘机械强度差、缺乏足够的支撑,尤其在高温高速下容易变形,电机性能下降,结构部件损坏,影响使用寿命。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.

发明内容Contents of the invention

本发明的目的就是为了克服上述现有技术存在的缺陷而提供一种运行效率高、延长电机使用寿命、机械强度高、散热性好的盘式无铁芯永磁电机的绕组结构及其制造方法。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 .

本发明的目的可以通过以下技术方案来实现:The purpose of the present invention can be achieved through the following technical solutions:

一种盘式无铁芯永磁电机的绕组结构,所述的绕组结构包括三个单相绕组盘和侧压板;所述的单相绕组盘周向互差120度电角度沿轴向叠放,三个单相绕组盘固定连接;所述的侧压板安装在顶部的三相绕组盘上。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.

优选地,所述的单相绕组盘包括单相线圈、绕组支架和灌封填充物;所述的单相绕组盘通过灌封填充物将单相线圈固定在绕组支架内。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.

更加优选地,所述的单相线圈由长条形薄片状铜材和绝缘纸交替并行连续叠绕而成,叠绕方向沿径向,气隙磁感线切割绕组的窄边,线圈相邻切割磁场的两个有效边平均节距为一个极距,有效边沿径向直线绕制,内侧端部或外侧端部交替环绕,侧端部和直线有效边轴向尺寸相同,均为铜薄片的宽边,并位于同一平面内,每相绕组仅有径向上1个位于内侧和1个位于外侧的接线端。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.

更加优选地,所述的绕组支架上设有定位支撑凸台;所述的定位支撑凸台的数量、形状和高度分别与盘式无铁芯永磁电机的极数、绕组的形状和高度相匹配。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.

更加优选地,所述的灌封填充物为环氧树脂。More preferably, the potting filler is epoxy resin.

更加优选地,所述的绕组支架和侧压板均由高强度高导热系数的复合材料制成。More preferably, both the winding bracket and the side pressure plate are made of composite materials with high strength and high thermal conductivity.

更加优选地,所述的绕组支架和侧压板的外圆周上分别设有位置互相对应的螺纹孔;所述的绕组支架和侧压板通过螺接实现绕组结构的一体化定位和支撑。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.

更加优选地,所述的三个单相绕组盘中的线圈通过长条形薄片状铜材连接,并焊接形成相间星接端。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.

更加优选地,所述的星接端进行包扎绝缘。More preferably, the star connection terminal is wrapped and insulated.

一种用于如上述任一项绕组结构的制造方法,所述的制造方法包括:A manufacturing method for any one of the above winding structures, the manufacturing method comprising:

步骤1:制作绕组支架、侧压板以及单相线圈;Step 1: Make the winding bracket, side plate and single-phase coil;

步骤2:将单相线圈绕组装配至绕组支架内,依靠绕组支架内的支撑凸台进行初始定位;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;

步骤3:使用灌封填充物灌注填充绕单相线圈绕组和定位支撑凸台之间的缝隙,形成独立的单相绕组盘;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;

步骤4:三个单相绕组盘周向互差120度电角度沿轴向叠放,采用薄片状铜材连接三相绕组,并焊接形成相间星接端;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;

步骤5:对星接端进行包扎绝缘;Step 5: Wrap and insulate the star terminal;

步骤6:在绕组支架有支撑凸台的一侧放置侧压板,采用螺钉连接三个单相绕组盘和侧压板,完成盘式无铁芯永磁电机绕组结构的制造。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.

与现有技术相比,本发明具有以下有益效果:Compared with the prior art, the present invention has the following beneficial effects:

一、运行效率高:本发明中的无铁芯永磁电机绕组结构采用单线圈沿轴向连续绕制制成成型绕组,减少了端部尺寸并彻底消除了线圈之间的连线,绕制时不需要在三维空间中弯折,保证绝缘品质,简化了制造工艺,减小了绕组的各项损耗,提高了电机的运行效率,同时节省了大量原料。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.

二、延长电机使用寿命:本发明中的无铁芯永磁电机绕组结构增强了绕组的机械强度、定位和散热,延长了电机的使用寿命和可靠运行。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.

三、机械强度高、散热性好:本发明中的无铁芯永磁电机绕组结构采用高强度、高导热性的绝缘凸台及其支架定位,机械强度增强,电机运行中绕组保持可靠定位,散热容易。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.

附图说明Description of drawings

图1为本发明实施例中无铁芯永磁电机的三相绕组线圈示意图;Fig. 1 is the schematic diagram of the three-phase winding coil of ironless permanent magnet motor in the embodiment of the present invention;

图2为本发明实施例中单相绕组盘的局部结构示意图;2 is a schematic diagram of a partial structure of a single-phase winding disc in an embodiment of the present invention;

图3为本发明实施例中单相线圈的结构示意图;Fig. 3 is a schematic structural diagram of a single-phase coil in an embodiment of the present invention;

图4为本发明实施例中线圈的结构示意图;FIG. 4 is a schematic structural view of a coil in an embodiment of the present invention;

图5为本发明实施例中绕组支架的结构示意图;Fig. 5 is a schematic structural diagram of a winding support in an embodiment of the present invention;

图6为本发明实施例中侧压板的结构示意图;Fig. 6 is a schematic structural view of a side pressure plate in an embodiment of the present invention;

图7为本发明实施例中经过灌封后单相绕组盘的结构示意图;Fig. 7 is a schematic structural view of a single-phase winding disk after potting in an embodiment of the present invention;

图8为本发明实施例中三个单相绕组盘叠放并制成星接端的结构示意图;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;

图9为本发明实施例中星接端包扎绝缘后的结构示意图;Fig. 9 is a schematic structural view of the star connection terminal after being bandaged and insulated in the embodiment of the present invention;

图10为本发明实施例中绕组结构的整体结构示意图;Fig. 10 is a schematic diagram of the overall structure of the winding structure in the embodiment of the present invention;

图11为本发明实施例中绕组结构制造方法的流程示意图。Fig. 11 is a schematic flowchart of a method for manufacturing a winding structure in an embodiment of the present invention.

图中标号所示:The numbers in the figure indicate:

1、单相绕组盘,2、侧压板,101、单相线圈,102、绕组支架,103、灌封填充物,104、定位支撑凸台。1. Single-phase winding disc, 2. Side pressure plate, 101. Single-phase coil, 102. Winding support, 103. Potting filler, 104. Positioning support boss.

具体实施方式Detailed ways

下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例是本发明的一部分实施例,而不是全部实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动的前提下所获得的所有其他实施例,都应属于本发明保护的范围。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.

一种盘式无铁芯永磁电机的绕组结构,其绕组线圈叠放方式如图1所示,其结构如图10所示,包括三个单相绕组盘1和一个侧压板2,单相绕组盘1周向互差120度电角度沿轴向叠放,三个单相绕组盘1固定连接,侧压板2安装在顶部的三相绕组盘上。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.

单相绕组盘的结构如图2、图3、图4、图5和图7所示,包括单相线圈101、绕组支架102和灌封填充物103,单相绕组盘1通过灌封填充物103将单相线圈101固定在绕组支架102内。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 .

单相线圈101的结构如图3和图4所示,由长条形薄片状铜材和绝缘纸交替并行连续叠绕而成,叠绕方向沿径向,气隙磁感线切割绕组的窄边,线圈相邻切割磁场的两个有效边平均节距为一个极距,有效边沿径向直线绕制,内侧端部或外侧端部交替环绕,侧端部和直线有效边轴向尺寸相同,均为铜薄片的宽边,并位于同一平面内,每相绕组仅有径向上1个位于内侧和1个位于外侧的接线端。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.

绕组支架102上设有定位支撑凸台104,定位支撑凸台104的数量、形状和高度分别与盘式无铁芯永磁电机的极数、绕组的形状和高度相匹配。定位支撑凸台104用于周向和径向上填充并定位绕组,确保绕组的有效边和端部在电磁力和热应力的作用下不发生较大的位移和变形。支架面向气隙一侧和侧压板为平面状。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.

本实施例选用的灌封填充物103为环氧树脂。The potting filler 103 selected in this embodiment is epoxy resin.

本实施例中的绕组支架102和侧压板2均由高强度高导热系数的复合材料,如聚酰亚胺、碳纤维、陶瓷等制成。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.

在绕组支架102和侧压板2的外圆周上分别设有位置互相对应的螺纹孔,绕组支架102和侧压板2通过螺接实现绕组结构的一体化定位和支撑。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.

本实施例还涉及一种用于上述绕组结构的制造方法,其流程如图11所示,包括:This embodiment also relates to a manufacturing method for the above-mentioned winding structure, the process of which is shown in Figure 11, including:

步骤1:制作绕组支架、侧压板以及单相线圈;Step 1: Make the winding bracket, side plate and single-phase coil;

步骤2:将单相线圈绕组装配至绕组支架内,依靠绕组支架内的支撑凸台进行初始定位;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;

步骤3:如图7所示,使用灌封填充物灌注填充绕单相线圈绕组和定位支撑凸台之间的缝隙,形成独立的单相绕组盘;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;

步骤4:如图8所示,三个单相绕组盘周向互差120度电角度沿轴向叠放,采用薄片状铜材连接三相绕组,并焊接形成相间星接端;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;

步骤5:如图9所示,对星接端进行包扎绝缘;Step 5: As shown in Figure 9, wrap and insulate the star terminal;

步骤6:在绕组支架有支撑凸台的一侧放置侧压板,采用螺钉连接三个单相绕组盘和侧压板,完成盘式无铁芯永磁电机绕组结构的制造。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.

需要指出的是,图1~10中所针对的电机以外转子电机为例,但本领域技术人员应熟知若电机为内转子电机,则位于内侧的接线端为三相绕组的星接端,外侧接线端为出线端;若为外转子电机,位于外侧的接线端为三相绕组的星接端,内侧接线端为出线端,制造工艺与内转子电机的绕组制造相同。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.

本实施例中的薄片状铜材优选采用H59-1黄铜带切割而成,绕制时需要绝缘纸并绕,如图4所示;也可采用MYFB-1、MYFB-2型绕包扁铜线,绕制时可以不需绝缘纸。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.

上述技术方案采用单线圈沿轴向连续绕制制成成型绕组,减少了端部尺寸并彻底消除了线圈之间的连线,绕制时不需要在三维空间中弯折,保证绝缘品质,简化了制造工艺,减小了绕组的各项损耗;绕组采用高强度、高导热性的绝缘凸台及其支架定位,机械强度增强,电机运行中绕组保持可靠定位,散热容易,延长了电机的使用寿命,提高运行效率,增强了绕组的机械强度、定位和散热,延长了电机的使用寿命和可靠运行,推动盘式无铁芯永磁电机应用于安装空间受限制、急需提高功率/转矩密度的航海、航空、电动汽车、精密伺服系统、新能源发电等领域,具有潜在的应用价值。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.

以上所述,仅为本发明的具体实施方式,但本发明的保护范围并不局限于此,任何熟悉本技术领域的技术人员在本发明揭露的技术范围内,可轻易想到各种等效的修改或替换,这些修改或替换都应涵盖在本发明的保护范围之内。因此,本发明的保护范围应以权利要求的保护范围为准。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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