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 PDFInfo
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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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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
- H02K15/0435—Wound windings
- H02K15/0442—Loop windings
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
- H02K15/0435—Wound windings
- H02K15/0464—Lap windings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
- H02K3/28—Layout of windings or of connections between windings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/46—Fastening of windings on the stator or rotor structure
- H02K3/47—Air-gap windings, i.e. iron-free windings
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
- H02K2203/12—Machines characterised by the bobbins for supporting the windings
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- Manufacturing & Machinery (AREA)
- Manufacture Of Motors, Generators (AREA)
Abstract
The invention relates to a winding structure of a disk-type coreless permanent magnet motor and a manufacturing method thereof, wherein the winding structure comprises three single-phase winding disks and side pressure plates, the single-phase winding disks are stacked in an axial direction with a circumferential difference of 120 degrees, the three single-phase winding disks are fixedly connected, and the side pressure plates are arranged on the three-phase winding disks at the top. 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, good heat dissipation and the like.
Description
Technical Field
The invention relates to the technical field of manufacturing of coreless permanent magnet motors, in particular to a winding structure of a disc type coreless permanent magnet motor and a manufacturing method thereof.
Background
At present, the disc type coreless permanent magnet motor has the advantages of high power/torque density, high efficiency, low torque fluctuation, stable operation and the like, and is rapidly popularized and applied to a direct-drive power generation system, a flywheel energy storage system, a high-precision servo system, a full-electric propulsion device system and the like.
The existing disc type coreless permanent magnet motor is generally provided with a surface-mounted permanent magnet in the circumferential direction of a rotor, the permanent magnet adopts a Halbach array to increase the sine degree of a magnetic field and air gap waveforms in the motor, and a stator is provided with no iron core and only comprises a winding and an insulating support material which is not magnetic and non-conductive, so that torque fluctuation caused by a tooth space effect does not exist. There are two winding structure types, a wound winding type for a large capacity motor and a printed circuit board type (PCB) for a small capacity motor. The application of the printed circuit board is limited due to poor heat dissipation and poor mechanical strength. And after the winding type winding is wound and molded, epoxy resin is poured to position the winding to form a winding disc, and high-strength composite materials such as polyimide, carbon fiber, ceramic and the like are adopted at two sides for packaging and reinforcing support.
The winding of the disc-type coreless permanent magnet motor is exposed to the environment of a strong magnetic field, and due to the influence of the skin effect and the proximity effect, the alternating current resistance is large, the eddy current loss is large, the efficiency is reduced, and the heat dissipation is influenced. Therefore, the wound winding material of the disc motor generally has the following modes: stranded fine electromagnetic round wire strands, litz wires, flat copper wires or sheet copper materials. The winding is formed by connecting a plurality of centralized independent coils in series and parallel according to phase zone division, the shape of each coil is circular, fan-shaped or polygonal, and the like, and compared with distributed coil windings, the overlapping of the coils is reduced, the size of the end part is small, and materials are saved.
The eddy current loss is reduced and the efficiency is improved to a certain extent by adopting the stranding of a plurality of strands of thin electromagnetic round wires or the winding of a litz wire, but the slot filling rate is reduced, the volume of the motor and the consumption of a permanent magnet are increased, and the power/torque density is reduced; the winding wound by adopting the flat copper wire or the sheet copper material has the advantages of small eddy current loss, high efficiency and high slot filling rate, but the insulation, especially the end part of the winding, is easy to damage at the bent part of the winding. The phase belt is divided and formed by connecting a plurality of centralized independent coils in series and parallel, the problems of more connecting wires between the coils and the coil groups and complex process exist, the size of the end part of the winding is still larger, the material consumption is large, and the efficiency needs to be further improved. Epoxy resin has low thermal conductivity, poor structural strength and easy deformation in a high-temperature environment, a winding disc positioned by epoxy resin encapsulation has poor mechanical strength and lacks sufficient support, and the winding disc is easy to deform at high temperature and high speed, the performance of a motor is reduced, structural parts are damaged, and the service life is influenced.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a winding structure of a disc coreless permanent magnet motor, which has the advantages of high operation efficiency, prolonged service life of the motor, high mechanical strength and good heat dissipation performance, and a manufacturing method thereof.
The purpose of the invention can be realized by the following technical scheme:
a winding structure of a disk-type coreless permanent magnet motor comprises three single-phase winding disks and side pressure plates; the single-phase winding discs are stacked in the axial direction with the mutual difference of 120 degrees in the circumferential direction, and the three single-phase winding discs are fixedly connected; and the side pressure plates are arranged on the three-phase winding disc at the top.
Preferably, the single-phase winding disc comprises a single-phase coil, a winding bracket and potting filler; the single-phase winding disc fixes the single-phase coil in the winding bracket through potting fillers.
More preferably, the single-phase coil is formed by alternately and continuously lapping and winding elongated flaky copper materials and insulating paper in parallel, the lapping and winding direction is radial, 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 end parts of the outer side are wound alternately, the axial sizes of the side end parts and the straight effective sides are the same, the side end parts and the straight effective sides are both wide sides of copper sheets and are located in the same plane, and each phase of winding only has 1 wiring terminal located on the inner side and 1 wiring terminal located on the outer side in the radial direction.
More preferably, the winding support is provided with a positioning support boss; the number, shape and height of the positioning support bosses are respectively matched with the number of poles of the disc-type coreless permanent magnet motor and the shape and height of the winding.
More preferably, the potting filler is epoxy resin.
More preferably, the winding support and the side pressure plates are both made of high-strength high-thermal conductivity composite materials.
More preferably, the winding support and the outer circumference of the side pressure plate are respectively provided with threaded holes corresponding to each other in position; the winding support and the side pressure plate realize integrated positioning and supporting of the winding structure through screw connection.
More preferably, the coils in the three single-phase winding disks are connected through an elongated laminar copper material and welded to form a phase-to-phase star connection end.
More preferably, the star connection end is wrapped and insulated.
A method of manufacturing a winding structure according to any one of the preceding claims, said method comprising:
step 1: manufacturing a winding support, a side pressing plate and a single-phase coil;
step 2: assembling the single-phase coil winding into a winding support, and performing initial positioning by virtue of a support boss in the winding support;
and step 3: filling gaps between the winding of the single-phase coil and the positioning support boss 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 a side pressing plate is arranged on one side of the winding support with the supporting boss, and the three single-phase winding discs and the side pressing plate are connected by screws to complete the manufacturing of the disc type coreless permanent magnet motor winding structure.
Compared with the prior art, the invention has the following beneficial effects:
1. the operation efficiency is high: the coreless permanent magnet motor winding structure adopts the single coil to continuously wind along the axial direction to form the formed winding, reduces the size of the end part and thoroughly eliminates the connecting line between the coils, does not need to bend in a three-dimensional space during winding, ensures the insulation quality, simplifies the manufacturing process, reduces various losses of the winding, improves the operating efficiency of the motor, and saves a large amount of raw materials.
2. The service life of the motor is prolonged: the winding structure of the coreless permanent magnet motor enhances the mechanical strength, positioning and heat dissipation of the winding, prolongs the service life of the motor and ensures reliable operation.
3. High mechanical strength, good heat dissipation: the winding structure of the coreless permanent magnet motor adopts the insulating boss with high strength and high thermal conductivity and the bracket thereof for positioning, the mechanical strength is enhanced, the winding keeps reliable positioning in the operation of the motor, and the heat dissipation is easy.
Drawings
FIG. 1 is a schematic diagram of a three-phase winding coil of a coreless permanent magnet motor in an embodiment of the present invention;
FIG. 2 is a partial schematic structural diagram of a single-phase winding disk according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of a single-phase coil according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of a coil structure according to 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 view of the structure of a side press plate according to an embodiment of the present invention;
FIG. 7 is a schematic structural diagram of a single-phase winding disc after potting in an embodiment of the invention;
FIG. 8 is a schematic structural diagram of three single-phase winding disks stacked and made into star connection ends in the embodiment of the present invention;
FIG. 9 is a schematic structural diagram of the embodiment of the invention after the star connection end is wrapped and insulated;
fig. 10 is an overall structural schematic diagram of a winding structure in an embodiment of the present invention;
fig. 11 is a schematic flow chart of a method for manufacturing a winding structure according to an embodiment of the present invention.
The reference numbers in the figures indicate:
1. the coil comprises a single-phase winding disc, 2, side pressure plates, 101, single-phase coils, 102, winding supports, 103, potting fillers, 104 and positioning support bosses.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. All other embodiments, which can be obtained by a person skilled in the art without making any creative effort based on the embodiments in the present invention, shall fall within the protection scope of the present invention.
A winding structure of a disk-type coreless permanent magnet motor is characterized in that a winding coil stacking mode is shown as figure 1, the winding structure is shown as figure 10, the winding structure comprises three single-phase winding disks 1 and a side pressing plate 2, the single-phase winding disks 1 are stacked in the axial direction with a circumferential difference of 120 degrees, the three single-phase winding disks 1 are fixedly connected, and the side pressing plate 2 is installed on a three-phase winding disk on the top.
The structure of the single-phase winding disc is shown in fig. 2, 3, 4, 5 and 7, and comprises a single-phase coil 101, a winding support 102 and potting fillers 103, wherein the single-phase winding disc 1 fixes the single-phase coil 101 in the winding support 102 through the potting fillers 103.
The structure of the single-phase coil 101 is as shown in fig. 3 and fig. 4, and the single-phase coil is formed by alternately and continuously winding elongated sheet copper materials and insulating paper in parallel, the winding direction is along the radial direction, the 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 linearly wound along the radial direction, the inner side end or the outer side end is alternately wound, the axial sizes of the side end and the linear effective side are the same, the side end and the linear effective side are both wide sides of copper sheets and are located in the same plane, and each phase of winding only has 1 terminal located inside and 1 terminal located outside in the radial direction.
The winding support 102 is provided with positioning support bosses 104, and the number, shape and height of the positioning support bosses 104 are respectively matched with the pole number of the disc-type coreless permanent magnet motor and the shape and height of the winding. The positioning support bosses 104 are used for filling and positioning the winding in the circumferential direction and the radial direction, and ensure that the effective edge and the end part of the winding are not subjected to 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.
The winding frame 102 and the side pressure plates 2 in this embodiment are made of a high-strength high-thermal-conductivity composite material, such as polyimide, carbon fiber, or ceramic.
Threaded holes corresponding to each other in position are respectively arranged on the outer circumferences of the winding support 102 and the side pressure plate 2, and the winding support 102 and the side pressure plate 2 are integrally positioned and supported by screwing.
The present embodiment also relates to a manufacturing method for the winding structure, the flow of which is shown in fig. 11, and the method includes:
step 1: manufacturing a winding support, a side pressing plate and a single-phase coil;
step 2: assembling the single-phase coil winding into a winding support, and performing initial positioning by virtue of a support boss in the winding support;
and step 3: as shown in fig. 7, the gap between the winding of the single-phase coil and the positioning support boss is filled with potting filler to form an independent single-phase winding disc;
and 4, step 4: as shown in fig. 8, three single-phase winding disks are stacked in the axial direction with a circumferential difference of 120 degrees, and are connected with a three-phase winding by using a sheet-shaped copper material and welded to form an interphase star connection end;
and 5: as shown in fig. 9, the star connection end is wrapped and insulated;
step 6: and a side pressing plate is arranged on one side of the winding support with the supporting boss, and the three single-phase winding discs and the side pressing plate are connected by screws to complete the manufacturing of the disc type coreless permanent magnet motor winding structure.
It should be noted that fig. 1 to 10 are directed to an external rotor motor as an example, but it should be known to those skilled in the art that if the motor is an internal rotor motor, the terminal located at the inner side is a star terminal of a three-phase winding, and the terminal located at the outer side is an outlet terminal; if the motor is an outer rotor motor, the wiring end positioned on the outer side is a star connection end of the three-phase winding, the wiring end positioned on the inner side is an outlet end, and the manufacturing process is the same as that of the winding of the inner rotor motor.
The flaky copper material in the embodiment is preferably cut by an H59-1 brass strip, and the copper material needs insulating paper to be wound in a parallel way when being wound, as shown in FIG. 4; MYFB-1 and MYFB-2 type lapping flat copper wires can also be adopted, and insulating paper is not needed during winding.
According to the technical scheme, the single coil is continuously wound along the axial direction to form the formed winding, so that the size of the end part is reduced, connecting lines among the coils are thoroughly eliminated, the coil does not need to be bent in a three-dimensional space during winding, the insulation quality is ensured, the manufacturing process is simplified, and various losses of the winding are reduced; the winding is positioned by adopting the high-strength and high-thermal-conductivity insulation boss and the support thereof, the mechanical strength is enhanced, the winding keeps reliable positioning in the operation of the motor, the heat dissipation is easy, the service life of the motor is prolonged, the operation efficiency is improved, the mechanical strength, the positioning and the heat dissipation of the winding are enhanced, the service life and the reliable operation of the motor are prolonged, the disc type coreless permanent magnet motor is promoted to be applied to the fields of navigation, aviation, electric automobiles, precise servo systems, new energy power generation and the like with limited installation space and urgent need of improving the power/torque density, and the disc type coreless permanent magnet motor has potential application value.
While the invention has been described with reference to specific embodiments, the invention is not limited thereto, and various equivalent modifications and substitutions can be easily made by those skilled in the art within the technical scope of the invention. Therefore, the protection scope of the present invention shall be subject to 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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| CN115395739A (en) * | 2022-10-28 | 2022-11-25 | 深圳大学 | Machining method of coreless flat wire disc type vertical axis wind driven generator |
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