KR20140004660U - Easily-assembled electric motor coil - Google Patents

Abstract

The easily assembled electric motor coil includes a first axis and a second axis perpendicular to the first axis. The electric motor coil is spooled radially outward about the first axis, and when the electric motor coil is fully spooled, the electric motor coil is curved in section on the second axis. Therefore, the curved coils can be attached directly to the inner surface of the silicon steel sleeve, thus accelerating manufacturing and increasing manufacturing efficiency. Also, the curved coil does not need to be pressurized and prevents damage to the structure of the curved coil caused by the pressing. The curved coil is spooled with a radian corresponding to the radian of the inner surface of the silicon steel sleeve. Therefore, the curved coil can be exactly the same height as the inner surface of the silicon steel sleeve.

Description

[0001] EASILY-ASSEMBLED ELECTRIC MOTOR COIL [0002]

The present invention relates to a novel easily assembled electric motor coil.

Conventional brushless electric motors generally include the following two types.

Referring to Fig. 8, the brushless electric motor has a silicon steel sleeve 911 and a plurality of teeth 912. The teeth 912 are formed on the inner surface of the silicon steel sleeve 911, and these teeth 912 are arranged annularly spaced apart from each other. The coil winding machine is inserted between two neighboring teeth 912 and spools the cord around one of teeth 912 during spooling. The coil winding machine repeats the operation until all the teeth 912 are surrounded by the coils 913. However, the gap between any two adjacent teeth 912 should be wide enough for the coil winding machine to wind the windings inside the stator 912. [ A gap of sufficient width still causes the inner surface of the silicon steel sleeve 911 to be unable to be spooled completely into the coils 913, which means that the coil space factor of the brushless electric motor can not be increased . Eventually, the output power is affected.

Referring to Fig. 9, due to the drawbacks of the limited coil dot rate of the brushless electric motor, manufacturers devise a coreless brushless electric motor. The cord is first spooled into a planar plane coil 922. A flat coil 922 is then mounted in the silicon steel sleeve 921. The silicone steel sleeve 921 does not have any teeth on the inner surface of the silicone steel sleeve 921. The plane coil 922 is pressed and deformed by the machine to be flush with the inner surface of the silicon steel sleeve 921. Thereafter, the plane coil 922 and the silicon steel sleeve 921 are bonded together. The above operation is repeated until the inner surface of the silicon steel sleeve 921 is fully mounted with the coils 922, thereby increasing the coil dot rate and resolving the drawbacks of conventional brushless electric motors.

However, the conventional manufacturing process of the coreless brushless electric motor has the following drawbacks.

First, each plane coil 922 must be pressed by the machine before it is flush with the inner surface of the silicon steel sleeve 921. Pressurization takes much more time and effort, and therefore the manufacturing efficiency of the coreless brushless electric motor can not be effectively increased.

Secondly, the plane coil 922 is pressed and deformed with radians. Pressurization and deformation can cause damage to the structure of the coil 922, easily causing a short circuit, affecting the output power and performance of the electric motor.

Thirdly, the radian of the coil 922 may not exactly correspond to the radian of the silicon steel sleeve 921, since the plane coil 922 is pressed and deformed with radians. Thus, a gap can be formed between the coil 922 and the inner surface of the silicon steel sleeve 921, which affects the function and performance of the coil 922. The gap not only reduces the coil drop, but also narrows the air gap between the coreless brushless electric motor and the rotor, causing the rotor to swing on the coils 922 when rotating, damaging the rotor and the coils 922 .

In order to overcome the drawbacks, the present invention provides a novel easily assembled electric motor coil for alleviating or eliminating the above mentioned problems.

The main purpose of the present invention is to provide a new easily assembled electric motor coil that accelerates the manufacturing process and increases manufacturing efficiency.

The easily assembled electric motor coil includes a first axis and a second axis perpendicular to the first axis. The electric motor coil is spooled radially outward about the first axis, and when the electric motor coil is fully spooled, the electric motor coil is curved in section on the second axis.

Advantages of the present invention are described below. The coil is spooled three-dimensionally and curved when spooling. Thus, compared to a conventional planar coil that needs to be pressed further to have its radian deformed, the curved coil of the present invention need not be pressurized and can be attached directly to the silicon steel sleeve, Thereby accelerating the manufacturing and increasing the manufacturing efficiency. Further, since the curved coil need not be pressed, the structure of the curved coil is not damaged. Finally, when formed, the curved coil is spooled with a radian corresponding to the radian of the inner surface of the silicon steel sleeve. Therefore, the curved coil can be exactly the same height as the inner surface of the silicon steel sleeve.

Other objects, advantages and novel features of the design will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is an operation diagram of a novel easily assembled electric motor coil according to the present invention, and shows a coil mounted on a silicon steel sleeve. Fig.
Figure 2 is a perspective view of a particular embodiment of a novel easily assembled electric motor coil in Figure 1;
Fig. 3 is an exploded perspective view of a particular embodiment of the novel easily assembled electric motor coil in Fig. 1;
Fig. 4 is another exploded perspective view of a particular embodiment of the novel easily assembled electric motor coil of Fig. 1;
Figure 5 is a partial side cross-sectional view of a particular embodiment of a novel easily assembled electric motor coil in Figure 1;
Figure 6 is a partial cross-sectional top view of a particular embodiment of a novel easily assembled electric motor coil in Figure 1;
FIG. 7 is a plan view of the novel easily assembled electric motor coil shown in FIG. 1, showing a curved coil of the same height as a silicon steel sleeve; FIG.
8 is a plan view of a conventional brushless electric motor according to the prior art.
Fig. 9 is an operation diagram of a conventional coreless brush-less electric motor according to the prior art.

Referring to FIG. 1, a first embodiment of a novel easily assembled electric motor coil 30 according to the present invention includes a first axis and a second axis. The second axis is perpendicular to the first axis. The electric motor coil 30 is spooled radially outward about the first axis and when the electric motor coil 30 is fully spooled, the electric motor coil 30 is curved in section on the second axis, On the axis, the cross section is elliptical. In a preferred embodiment, the cord used to spool the electric motor coil 30 may be enameled, and the material of the cord is preferably copper, aluminum or a combination thereof, but is not limited thereto.

Next, the process of spooling the electric motor coil 30 is described as follows: Referring to Figs. 2 to 6, a specific embodiment 10 is prepared. The specific embodiment 10 has a first axis, a second axis, a male mold 11, an arm mold 12, an inner space 14 and a central mold 13. The male mold (11) has a curved protrusion (111). The arm mold 12 has a curved groove 121. The arm mold 12 is connected to the male mold 11 along the first axis. An internal space 14 is formed between the curved protrusion 111 of the male mold 11 and the curved groove 121 of the arm mold 12 and the curved protrusion 111 and the curved groove 121 The shapes correspond to each other. The inner space 14 is curved in cross section on the second axis and communicates with the outer environment through the two ends of the curved shape of the inner space 14, And communicates with the external environment through the directions. The arm mold 12 has an exit groove 122 formed in the curved groove 121 and extends along one of the two opposite directions on the second axis to communicate with the external environment. A central mold 13 is mounted between the male mold 11 and the female mold 12 and is mounted through the inner space 14. [ The central mold 13 is elliptical in cross section on the first axis. During spooling, the cord 20 is inserted into the inner space 14 from one of two opposite directions on the second axis, surrounding the central mold 13, mounted within the outlet groove 122, (14) and protrudes out of the inner space (14) in a direction opposite to the inserting direction. The particular implementation 10 is then rotated about the first axis. The cord 20 is spooled around the rotating central mold 13 and the cord 20 is spooled along the curved shape of the inner space 14 to form a curved coil 30. [ After the curved coil 30 is spooled, the excess cord 20 is cut off. The male mold 11 and the arm mold 12 are separated from each other and the curved coil 30 is removed from the central mold 13. [ In a preferred embodiment, the material of the particular embodiment 10 is selected from the group consisting of steel, silicon steel, iron, plastic and resin, but is not limited thereto.

Referring to Figures 1 and 7, when a curved coil 30 is used and mounted on a silicon steel sleeve 40 as described, first a plurality of curved coils 30 are mounted in the same manner as mentioned above . Next, a silicon steel sleeve 40 is prepared, wherein the radian of the curved coil 30 is the same as the radian of the inner surface of the silicon steel sleeve 40. One of the curved coils 30 is then slid into the silicon steel sleeve 40 along the inner surface of the silicon steel sleeve 40 to cause the curved coil 30 to move to the inner surface of the silicon steel sleeve 40 As shown in FIG. The curved coil 30 is then attached to the inner surface of the silicon steel sleeve 40 by glue. The other curved coils 30 are bonded to the silicon steel sleeve 40 in the same manner to ensure that the inner surface of the silicon steel sleeve 40 is fully mounted with curved coils 30 that are parallel or overlapping each other.

Because the curved coil 30 is already curved at the time of spooling, the curved coil 30 not only has to be the same height as the silicon steel sleeve 40, but at the same time, the silicon steel sleeve 40, along the inner surface of the silicon steel sleeve 40, (Not shown). The manufacture of the novel electric motor windings can be accelerated and thus the manufacturing efficiency is increased. Without the need to pressurize and deform, the curved coil 30 can avoid damage that affects electrical conduction and output power. Finally, the curved coil 30 is spooled with a radian corresponding to the radian of the silicon steel sleeve 40 so that the curved coil 30 can be exactly the same height as the inner surface of the silicon steel sleeve 40 have.

In summary, the easily assembled electric motor coil 30 as described can reduce damage during fabrication and can be exactly the same height as the silicon steel sleeve 40, raising manufacturing efficiency.

In addition, the easily assembled electric motor coil 30 as described can be used in a variety of electric motor applications such as DC motors, induction motors, permanent magnet motors, and reluctance motors.

In addition, the easily assembled electric motor coils can be mounted on the silicon steel sleeve in other ways. The curved coils are first brought to the same height as the inner surface of the silicon steel sleeve. When the inner surface of the silicon steel sleeve is completely mounted with curved coils that are parallel or overlapping each other, the curved coils are attached to the inner surface of the silicon steel sleeve by the glue. The method of mounting the electric motor coil on the silicon steel sleeve can also increase the manufacturing efficiency.

Although many features and advantages of the present invention have been disclosed in the foregoing description, along with the details of the structure and features of the design, the disclosure is only exemplary. Changes may be made to the details in matters of shape, size, and arrangement of parts within the full scope, in particular in the principles of design, as broadly indicated by the broad general meaning of the terms of the appended claims.

Claims (3)

An electric motor coil comprising: a first axis and a second axis perpendicular to the first axis, the electric motor coil being spooled radially outwardly about the first axis, the electric motor coil being completely Wherein said electric motor coil when spooled is curved in section on said second axis. The method according to claim 1,
Wherein the electric motor coil is elliptical in cross-section on the first axis when the electric motor coil is fully spooled. 3. The method according to claim 1 or 2,
Wherein the material of the electric motor coil is copper, aluminum or a combination thereof.

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