WO2001013494A1 - Piles d'enroulements isolees pour bobines a enroulements de phase, utilisees dans des dispositifs electromoteurs - Google Patents

Piles d'enroulements isolees pour bobines a enroulements de phase, utilisees dans des dispositifs electromoteurs Download PDF

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Publication number
WO2001013494A1
WO2001013494A1 PCT/US2000/021809 US0021809W WO0113494A1 WO 2001013494 A1 WO2001013494 A1 WO 2001013494A1 US 0021809 W US0021809 W US 0021809W WO 0113494 A1 WO0113494 A1 WO 0113494A1
Authority
WO
WIPO (PCT)
Prior art keywords
insulated
phase windings
winding
stack
winding stack
Prior art date
Application number
PCT/US2000/021809
Other languages
English (en)
Inventor
Ha T. Pham
Lawrence G. Campitiello
Original Assignee
Bei, Kimco Magnetics Division
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Bei, Kimco Magnetics Division filed Critical Bei, Kimco Magnetics Division
Publication of WO2001013494A1 publication Critical patent/WO2001013494A1/fr

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K7/00—Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
    • H02K7/10—Structural association with clutches, brakes, gears, pulleys or mechanical starters
    • H02K7/116—Structural association with clutches, brakes, gears, pulleys or mechanical starters with gears
    • H02K7/1163—Structural association with clutches, brakes, gears, pulleys or mechanical starters with gears where at least two gears have non-parallel axes without having orbital motion
    • H02K7/1166—Structural association with clutches, brakes, gears, pulleys or mechanical starters with gears where at least two gears have non-parallel axes without having orbital motion comprising worm and worm-wheel
    • 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
    • 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
    • H02K15/10—Applying solid insulation to windings, stators or rotors
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K29/00—Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices
    • H02K29/06—Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices with position sensing devices
    • H02K29/08—Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices with position sensing devices using magnetic effect devices, e.g. Hall-plates, magneto-resistors
    • 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

Definitions

  • This invention relates to the field of electromotive devices such as electric motors and generators. More specifically, this invention concerns an apparatus and method used in forming the phase windings, also known as “field coils” or “windings,” used in the stators of electromagnetic devices. The invention eliminates parasitic power losses due to "cogging” and allows the field coils to be left in place after they are wound. Although this invention has wide applicability, it is particularly useful in forming the stator phase windings of a brushless DC motor, as described below.
  • FIG. 1 A cross-section of a conventional stator is shown in FIG. 1.
  • the coils are wound around "teeth" formed by ferromagnetic stator laminations. Slot insulation separates the windings from the teeth.
  • Cogging can lead to problems in electromotive devices, including increased vibrations, noise and increased core losses. As the rotor speed increases, these problems increase proportionally.
  • the slotless stator design eliminates the slot variation, since there are no ferromagnetic materials interspersed with the phase windings in the magnetic gap ( i . e . , the distance between the rotor and the outer ring) .
  • This design eliminates the problems caused by cogging and can produce a higher-efficiency device.
  • the rotor magnet must be stronger than the magnet used with a conventional stator because the conventional slotless stator design has a larger effective magnetic gap.
  • This effective magnetic gap is the sum of the air gap, plus the inner insulating ring, plus the radial distance of the phase windings, plus the outside insulating ring.
  • the effective magnetic gap includes the entire radial distance between the outer diameter (O.D.) of the rotor magnet and the inner diameter (I.D.) of the outer ring. See FIG. 2.
  • phase windings take up most of the space in the effective magnetic gap, typically about 90%. To maintain the smallest effective magnetic gap, the phase windings must be as flat as possible. Therefore, the key to building an efficient and cost effective slotless stator is the method for winding and positioning the field coils. If concentric windings are desired, the windings must be roughly consistent in radial width to maintain concentricity between the I.D. of the outer ring and the O.D. of the rotor. Good concentricity of the windings allows the air gap to be minimized.
  • an insulated winding stack provides a structure on which phase windings can be wound m their proper position
  • the phase windings and winding stack are incorporated as a unit into the electromotive device
  • a stator formed with the insulated winding stack of the present invention eliminates the "cogging" effect caused by the steel teeth of a conventional stator After the phase windings are formed, the windings remain on the insulated winding stack and may be impregnated with a bonding agent to maintain the integrity of the windings .
  • FIG 1 illustrates a cross-section of a conventional stator, wherein phase windings are formed around insulated steel teeth.
  • FIG.2 illustrates a partial cross-section of an idealized conventional slotless stator.
  • FIG. 3 illustrates the first step m a conventional method of winding the phase windings of a conventional slotless stator, wherein the phase windings are formed prior to being laid on an inner insulating ring of the stator.
  • FIG. 4 illustrates the coil lay-up step m a conventional method of winding the phase windings of a conventional slotless stator, wherein the phase windings are laid on an inner insulating ring of the stator. In this instance, the phase windings are laid m an overlapping "wave" pattern.
  • FIGS. 5a and 5b illustrate the coil forming steps of forming the phase windings of a conventional slotless stator.
  • FIG. 5a illustrates the step of bending the field coils to conform with the curved surface of the inner insulating ring.
  • FIG. 5b an outside insulating ring has been fitted over the outside of the phase windings.
  • FIG. 6 is a cross-section of a stator which illustrates a portion of one embodiment of the present invention, m which the teeth of the insulated winding stack have been formed to receive concentric phase windings .
  • FIG 7 illustrates the insulated winding stack of FIG 6, with Hall effect devices positioned between some of the phase coils, with an outer ring (e.g., a stack of soft steel laminations) fitted on outside the insulated winding stack and a rotor magnet inside the insulated winding stack.
  • an outer ring e.g., a stack of soft steel laminations
  • FIG. 8 illustrates a perspective view of an embodiment of the insulated winding stack wherein the teeth extend the full length of the winding stack.
  • FIG. 9 illustrates a perspective view of a removable plug and an embodiment of the insulated winding stack.
  • FIG. 10 illustrates a perspective view of a removable plug and an embodiment of the insulated winding stack, wherein the plug has been inserted into the winding stack.
  • FIG. 11 illustrates a portion of a cross-section of a cylindrical insulated winding stack, enlarged to reveal the shape of an individual tooth.
  • FIG. 12 illustrates a portion of a cross-section of a planar insulated winding stack, enlarged to reveal the shape of an individual tooth.
  • FIG. 6 illustrates one embodiment of the present invention wherein insulated winding stack 1 is formed to receive three pairs of phase windings.
  • the phase windings may be formed of any suitable conducting material, such as copper, and should be insulated.
  • the number of pairs of phase windings illustrated m FIG. 6 is purely illustrative; any convenient number may be used.
  • Insulated winding stack 1 can be formed from one or more pieces of non-conductive material, such as high-temperature injection-molded plastic, a fire- resistant paper product (e . g. , Dupont "NOMEX”) or other insulating material .
  • the insulating material may be stacked and bonded like conventional motor laminations .
  • insulated winding stack 1 provides a structure on which phase windings 5, 7, 9, 11, 13 and 15 can be wound.
  • Insulated winding stack 1 can be mounted on a winding mandrel and the phase windings can be wound onto the insulated stack.
  • a conventional outside winding machine used to make brush type motor armatures may be used to wind phase windings on insulated winding stack 1.
  • insulated stack 1 may be held stationary while the phase windings are wound.
  • Insulated winding stack 1 and phase windings 5 , 7, 9, 11, 13 and 15 are later incorporated as a unit into the electromotive device After phase windings 5, 7, 9, 11, 13 and 15 are formed, they remain on the insulated winding stack 1
  • the entire assembly can be impregnated with a bonding agent m order to keep phase windings 5, 7, 9, 11, 13 and 15 m their proper positions.
  • FIGS. 9 and 10 if the assembly is heated to cure the bonding agent, removable plug 21 may be inserted into the inside diameter (I.D.) of insulated winding stack 1 in order to maintain its shape.
  • I.D. inside diameter
  • FIG. 7 it is important that the I.D. of insulated winding stack 1 be accurately maintained, because there should be a very small space between the outside diameter (O.D.) of rotor magnet 20 and the I.D. of insulated winding stack 1.
  • an outer ring 17 can be fitted over the insulating winding stack.
  • the outer ring may be made of any suitable ferromagnetic material, such as steel laminations.
  • the insulating properties of the outer part of insulated winding stack 1 protect phase windings 5, 7, 9, 11, 13 and 15 from electrically shorting out to outer ring 17.
  • the insulated winding stack 1 includes projections or "teeth" 2 which are formed to receive phase windings.
  • teeth 2 extend the full length of the winding stack, as illustrated in FIG. 8.
  • Insulated winding stack 1 can vary in length and diameter to accommodate the size of the rotor and the performance of the electromotive device .
  • FIG. 11 provides an enlarged view of a single tooth 2 and a portion of insulating core 6 of insulated winding stack 1.
  • core 6 is cylindrical in shape.
  • FIG. 11 reveals that each tooth 2 comprises stem 4 and cap 8.
  • FIG. 12 provides an enlarged view of a single tooth 2A and a portion of insulating core 6A of insulated winding stack 1.
  • Core 6A is planar in shape.
  • FIG. 12 shows that each tooth 2A comprises stem 4A and cap 8A.
  • teeth 2 illustrated in FIGS. 6-12 are roughly "T" shaped in cross-section, any convenient shape may be used.
  • the O.D. of insulated winding stack 1 may change as a result of the curing process, especially if the assembly is heated to cure the bonding agent.
  • a stator formed with insulated winding stack 1 of the present invention eliminates the "cogging" effect caused by the metal teeth of a conventional stator. Moreover, the design of the present invention provides excellent concentricity between the O.D. and I.D. of the phase windings 5, 7, 9, 11, 13 and 15 if a concentric winding pattern is used. As shown in FIG. 7, this concentricity allows the gap between the O.D. of rotor magnet 20 and the I.D. of outer ring 17 to be minimized, thereby improving motor performance .
  • insulated winding stack 1 is used to form concentric windings for the stator of a brushless direct current ("D.C.") motor.
  • Hall Effect devices are needed to provide commutation signals. Hall Effect devices must be accurately positioned in relation to the phase windings in order to provide accurate timing signals.
  • Hall Effect devices In a conventional stator for a slotless, brushless D.C. motor, Hall Effect devices must be manually positioned and the timing of each Hall Effect device must be manually checked.
  • the positions of Hall Effect devices 19 are fixed and are placed into the slots between teeth 2 of insulated winding stack 1. See FIG 7 Teeth 2 are formed such that these slots are midway between adjacent phase windings 5, 7, 9, 11, 13 and 15, and m the proper ratio to allow precise positioning of Hall Effect devices 19.
  • this embodiment of the present invention provides more accurate positioning of Hall Effect devices 19 and allows for Hall Effect devices 19 to be positioned by machine. More accurate positioning of Hall Effect devices 19 increases timing accuracy and improves motor performance.
  • the present invention eliminates the need for manual timing adjustments, which are required m conjunction with the prior art method of positioning the phase windings by hand.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Insulation, Fastening Of Motor, Generator Windings (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)

Abstract

Selon cette invention, une pile d'enroulements isolée permet de former une structure dans laquelle les enroulements de phase peuvent être enroulés en position voulue. Les enroulements de phase et la pile de bobines sont réunis en une seule unité, qui est intégrée au dispositif électromoteur. Dans cette invention, un stator formé avec la pile d'enroulement isolée permet d'éliminer l'effet d'engrènement provoqué par les dents métalliques d'un stator traditionnel. Une fois les bobinages de phase formés, les bobines restent fixées à la pile de bobinages isolée et peuvent être imprégnées avec un agent liant afin que l'intégrité des enroulements soit préservée.
PCT/US2000/021809 1999-08-12 2000-08-10 Piles d'enroulements isolees pour bobines a enroulements de phase, utilisees dans des dispositifs electromoteurs WO2001013494A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US37335099A 1999-08-12 1999-08-12
US09/373,350 1999-08-12

Publications (1)

Publication Number Publication Date
WO2001013494A1 true WO2001013494A1 (fr) 2001-02-22

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2000/021809 WO2001013494A1 (fr) 1999-08-12 2000-08-10 Piles d'enroulements isolees pour bobines a enroulements de phase, utilisees dans des dispositifs electromoteurs

Country Status (1)

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WO (1) WO2001013494A1 (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102005036108A1 (de) * 2005-08-01 2007-02-08 Minebea Co., Ltd. Elektrische Maschine, insbesondere bürstenloser Gleichstrommotor für ein Festplattenlaufwerk
JP2013198398A (ja) * 2012-03-21 2013-09-30 Maxon Motor Ag 中空円筒型空芯巻線
KR101426170B1 (ko) * 2012-12-28 2014-08-07 주식회사 효성 슬롯 레스용 전동기 고정자
JP2016532419A (ja) * 2013-10-07 2016-10-13 ムービング マグネット テクノロジーズ （ソシエテ アノニム）Ｍｏｖｉｎｇ Ｍａｇｎｅｔ Ｔｅｃｈｎｏｌｏｇｉｅｓ （Ｓ．Ａ．） 集中巻線を有するスロットレス電気機械
WO2018015394A1 (fr) * 2016-07-21 2018-01-25 Ebm-Papst Mulfingen Gmbh & Co. Kg Moteur à vitesse élevée avec enroulement non jointif

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4709180A (en) * 1985-11-20 1987-11-24 The Garrett Corporation Toothless stator construction for electrical machines
US5030877A (en) * 1985-11-20 1991-07-09 Allied-Signal Inc. Turbine engine with integral clam shell dynamoelectric machine
US5323075A (en) * 1992-11-20 1994-06-21 Alliedsignal Inc. Hall effect sensors embedded within two-pole toothless stator assembly
US5525850A (en) * 1994-05-20 1996-06-11 Penn Engineering & Manufacturing Corp. Brushless motor stator-winding system
US5714827A (en) * 1993-05-26 1998-02-03 Atlas Copco Tools Ab Stator for an electric machine
US5850318A (en) * 1995-06-06 1998-12-15 Seagate Technology, Inc. Slotless spindle motor for disc drive

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4709180A (en) * 1985-11-20 1987-11-24 The Garrett Corporation Toothless stator construction for electrical machines
US5030877A (en) * 1985-11-20 1991-07-09 Allied-Signal Inc. Turbine engine with integral clam shell dynamoelectric machine
US5323075A (en) * 1992-11-20 1994-06-21 Alliedsignal Inc. Hall effect sensors embedded within two-pole toothless stator assembly
US5714827A (en) * 1993-05-26 1998-02-03 Atlas Copco Tools Ab Stator for an electric machine
US5525850A (en) * 1994-05-20 1996-06-11 Penn Engineering & Manufacturing Corp. Brushless motor stator-winding system
US5850318A (en) * 1995-06-06 1998-12-15 Seagate Technology, Inc. Slotless spindle motor for disc drive

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102005036108A1 (de) * 2005-08-01 2007-02-08 Minebea Co., Ltd. Elektrische Maschine, insbesondere bürstenloser Gleichstrommotor für ein Festplattenlaufwerk
JP2013198398A (ja) * 2012-03-21 2013-09-30 Maxon Motor Ag 中空円筒型空芯巻線
KR101943111B1 (ko) * 2012-03-21 2019-01-28 맥슨 모터 아게 중공 원통형 코어리스 권선
KR101426170B1 (ko) * 2012-12-28 2014-08-07 주식회사 효성 슬롯 레스용 전동기 고정자
JP2016532419A (ja) * 2013-10-07 2016-10-13 ムービング マグネット テクノロジーズ （ソシエテ アノニム）Ｍｏｖｉｎｇ Ｍａｇｎｅｔ Ｔｅｃｈｎｏｌｏｇｉｅｓ （Ｓ．Ａ．） 集中巻線を有するスロットレス電気機械
WO2018015394A1 (fr) * 2016-07-21 2018-01-25 Ebm-Papst Mulfingen Gmbh & Co. Kg Moteur à vitesse élevée avec enroulement non jointif

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