JP2016500510A - Synchronous motor manufacturing method - Google Patents

Abstract

The present invention relates to a method of manufacturing a synchronous motor and a synchronous motor. Said stator (100) is formed as an external stator and has at least two poles and slots (1-12), said slots comprising stator windings (37). In order to be able to produce a small and very fast synchronous motor at the lowest possible cost, according to the invention, the stator (100) is separated before the stator winding (37) is mounted. The stator windings (37) are developed in one band-like portion, passed through the slots (1-12), guided in the axial direction, then guided radially outward, and then along the outer surface of the stator. It is folded back in the axial direction, after which the strip is closed annularly.

Description

  The invention relates to a method for manufacturing a synchronous motor according to the superordinate concept of claim 1 and to a synchronous motor manufactured using this type of method according to claim 9.

  Synchronous motors are used in many technical fields. A small, very fast rotating synchronous motor has few poles, typically two poles, and a relatively large copper cross section. This causes an increase in the size of the winding main body, and accordingly, the axial length between the motor bearings is also limited, so that the length of the iron core in the axial direction must be reduced.

  The windings around the individual teeth of the synchronous motor help to avoid such problems, but at the same time are likely to cause significant losses, in which case only limited power densities can be achieved. This is because only a small portion of about half of the total magnetic flux is coupled to the winding.

  In the case of a typical synchronous motor that is small and rotates at a very high speed, a uniform and sinusoidal field distribution is particularly desirable. This requires a three-phase winding with the desired distribution as much as possible. This may be a typical two-layer winding, for example. However, in the case of a small synchronous motor, this causes a result that the copper cross section to be introduced must be larger than the free cross section of the stator internal diameter due to the combination of a large copper cross section and a small diameter of the stator internal diameter. Therefore, the introduction of the winding from the inside is very expensive.

  The problem on which the present invention is based is to provide a method which allows a simple production of a synchronous motor which requires only a short winding length and which is particularly small and which rotates at a very high speed.

  According to the invention, the problem is solved by the invention as described in the characterizing parts of claims 1 and 9. Advantageous refinements of the invention are also described in the dependent claims.

  According to the method of manufacturing a synchronous motor according to the present invention, the stator is configured as an external stator and has at least two poles and slots, the slots comprising stator windings. Before the stator winding is mounted, it is separated and developed into one band-like portion, and the stator windings are respectively guided through the slots in the axial direction, then guided radially outward, and subsequently on the outer surface of the stator. And then the band is closed annularly.

According to such a method, a synchronous motor that is small and rotates at a very high speed, for example, a synchronous motor having a rotation speed of 100,000 min ⁻¹ or more can be manufactured at a relatively low cost. Become. By separating and unfolding the stator, the winding can be easily formed, and the copper cross section at that time can be made larger than the diameter of the stator inner diameter without any problem. In particular, a coil with a relatively short wire length is obtained by guiding outward in the radial direction and axial folding along the outer surface of the stator yoke. Therefore, in the return region that is folded back along the outer peripheral surface of the stator, the stray inductance can be controlled without much cost. For example, the stray inductance can be increased or decreased without significantly changing the basic function of the synchronous motor, depending on the design of the stator core in the folded region. This also makes it possible to replace the choke that would otherwise be required. During the operation, the windings to be folded may be actively or as necessary cooled.

  In order to achieve a uniform, in particular sinusoidal field distribution, the stator winding is advantageously implemented as a three-phase winding, in particular as a two-layer winding. These windings may be as desired. The stator can advantageously be separated in the slot region. Such separation can be performed relatively easily. This is because the stator in the slot region has a smaller cross section than the pole region. For a good development of the stator, in this case it may be advantageous to carry out a partial separation starting radially inward in a further slot region in addition to a complete separation of one slot region. For example, such partial separation may be performed in each second slot, i.e. every other slot. In these slots, windings with different phases are preferably arranged.

  According to an alternative embodiment, the stator is completely separated in one pole, with a partial separation starting from the radial inside in a further pole. In this case, in particular, one separation is performed for each second pole. This incurs manufacturing costs for the separation, but reduces the risk of winding errors.

  According to an advantageous embodiment, each slot is divided into a right half and a left half, and in each of these halves a coil layer is arranged adjacent in the circumferential direction. Thereby, the required wire length can be shortened.

  The subject is also a synchronous motor according to the present invention, comprising a stator configured as an external stator and having at least two poles and a slot, the slot being wound by a stator winding. Manufactured by the method according to the invention described above, wherein the stator has at least one particularly closed separation point, the stator windings being passed through one slot in the axial direction and guided radially outwards, The problem is solved by being guided back in the axial direction along the outer surface of the stator. This type of synchronous motor can be configured as a small and very fast synchronous motor, which has a sufficiently large copper cross-section and a uniform field distribution. The combination of a large copper cross section and a small stator inner diameter can be realized without any problems. This type of synchronous motor can be manufactured at low cost and correspondingly inexpensively.

  Due to the field distribution as uniform as possible and in particular sinusoidal, the stator winding can advantageously be designed as a three-phase winding, in particular as a two-layer winding.

  A particularly simple embodiment is obtained by forming the separation point in the region of one slot. In that case, in particular, in every other slot region, at least a partial separation is formed, starting from the radially inner side of the stator and extending radially outward.

  According to an alternative embodiment, the separation point can also be formed in one polar region, except for a slightly increased cost. In this case, in particular, partial separation points are formed in every other polar region.

  The number of poles of the synchronous motor is preferably equal to 2. Thereby, it is possible to form a synchronous motor that is small and rotates at a very high speed.

  By using a corresponding ratio between the axial length of the synchronous motor and its diameter, a short wire length can be achieved by connection with the winding according to the invention.

  The advantageous aspects of the invention that have been described in connection with the manufacturing method are of course also applicable to synchronous motors manufactured using this method and are valid for others.

  In the drawing, an embodiment of the present invention is shown.

A three-dimensional representation of the stator deployed as a strip Figure showing a stator with stator windings Diagram showing typical winding pattern The figure which showed the winding pattern by this invention

Example FIG. 1 shows a stator 100 deployed as a strip having a plurality of slots 1-12. The plurality of slots 1 to 12 are formed between the pole teeth 13 to 24 of the stator 100. The complete separation point 25 forms the end of the band-like portion that has been so developed. In each second slot or every other slot 2, 4, 6, 8, 10 there are formed partial separation points 26, 27, 28, 29, 30 so that the stator Are divided into a plurality of circular pitch-shaped segments 31, 32, 33, 34, 35, and 36. The slot 1 exists in the circular pitch-shaped segment 31 following the complete separation point, and is present at the leftmost end in the depiction of FIG. For example, the individual circular pitch-like segments 31-36 are positive from phase 1 to left, positive in phase 1, negative in 2, negative in 3, positive in 1, negative in 2, positive in 3, It may be wound.

  After winding, the stator 100 is closed in a circle, thereby bringing it into its final form. The stator 100 that has been wound is shown in FIG. Here it can be seen that the stator winding 37 is guided axially through the slot and then extends radially outward. This is because it continues to be pulled back over the outer surface 38 of the stator 100 in the axial direction. Thereafter, the stator windings are folded back radially inward and guided again into the respective slots.

  Here, it can be seen that the diameter of the stator inner diameter 39 is smaller than the copper cross section. Nevertheless, according to the manufacturing method according to the invention, such a synchronous motor can be produced at a relatively low cost.

  FIG. 3 shows a typical winding pattern of a shortened two-layer winding. The coil starts in slot 1 and is guided in the positive axial direction through slot 1. When this coil reaches the slot 6 over the circumferential surface, it is guided there through the slot in the negative axial direction. Subsequently, the coil is returned to the slot 1 over the circumferential surface.

  In this type of winding, the wire length of the coil corresponds to the axial length × 2 and the length of the end surface side section × 2 along the circumferential surface. For those lengths, the coil passes current in the positive direction in slot 1 and in the negative direction in slot 6.

  In the winding pattern according to the present invention, as shown in FIG. 4, the same coil of phase 1 in the slot 1 is guided in the positive axial direction through the slot 1, and then guided radially outward, It is folded back in the negative axial direction over the outer surface of the yoke or stator, and is then guided radially inward and returned to the slot 1 again. In this case, each slot is divided into two halves adjacent in the circumferential direction, for example, a right half and a left half. The wire length of the coil wound in this way corresponds to (axial length × 2) + (radial length × 2). The current here is guided positively or negatively through the slot. Two coils are required to obtain the same effect as with a typical winding pattern.

  There are advantageously layers of different phases in the slots having the separation points for deploying the stator 100. In the present embodiment, this corresponds to a slot having an even slot number.

  According to the present invention, by providing at least one separation point in the stator and combining with a specific winding pattern, a small-sized synchronous motor that rotates at a very high speed can be manufactured at low cost. Further, in this electric motor, the wire length of the winding can be kept short. In this case, the copper cross section can be formed larger than the cross section of the stator inner diameter without any problem, and correspondingly powerful performance can be formed.

Claims (12)

In a method of manufacturing a synchronous motor, wherein the stator (100) is formed as an external stator and has at least two poles and slots (1-12), said slots comprising a stator winding (37),
Separating the stator (100) before mounting the stator winding (37) and developing it into one strip-shaped portion;
The stator windings (37) are guided axially through the slots (1-12), respectively, and then guided radially outward, and subsequently folded back axially along the outer surface (38) of the stator, Thereafter, the band-like portion is annularly closed.   The method according to claim 1, wherein the stator winding is formed as a three-phase winding, in particular as a two-layer winding.   The method according to claim 1 or 2, wherein the stator (100) is separated in the region of one slot (12).   The stator (100) is completely separated in one slot (12) and further separated in a further slot (2, 4, 6, 8, 10), starting from the radial inside, in particular 1 The method of claim 3, wherein one separation is performed for every other slot.   The method according to claim 3 or 4, wherein in said slot (2, 4, 6, 8, 10, 12) having one separation, said winding (37) is installed in different phases.   The method of claim 1 or 2, wherein the stator (100) is separated in one pole region.   The stator (100) is completely separated at one pole and further separated at the further pole starting from the radial inside, in particular one separation is performed for every other pole. The method of claim 6.   8. A method according to any one of the preceding claims, wherein each slot (1-12) is divided into a right half and a left half where one coil layer is arranged. A synchronous motor comprising a stator (100),
In the synchronous motor, the stator (100) is configured as an external stator and has at least two poles and slots (1-12), the slots being wound by a stator winding (37) ,
The synchronous motor is manufactured by the method of any one of claims 1 to 8, wherein the stator (100) has at least one particularly closed separation point (25),
The stator windings (37) are each guided through one slot (1-12) in the axial direction, guided radially outward, and further folded back along the outer surface (38) of the stator (100) in the axial direction. Synchronous motor characterized by being returned.   10. The synchronous motor according to claim 9, wherein the stator winding (37) is formed as a three-phase winding, in particular as a two-layer winding.   Said separation point (25) is formed in the region of one slot (12), in particular at least partially in the region of every other slot (2, 4, 6, 8, 10). The synchronous motor according to claim 9 or 10, wherein the points (26 to 30) are formed.   The synchronous motor according to claim 9 or 10, wherein the separation portion is formed in one pole region, and at least a partial separation portion is formed particularly in every other pole region.

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