阅读说明：本技术 一种高效率直流无刷空心杯定子绕线工装及制作方法 (High-efficiency direct-current brushless coreless stator winding tool and manufacturing method ) 是由 张伟 袁志军 朱如意 许聪 张昊 于 2021-08-16 设计创作，主要内容包括：本发明公开了一种高效率直流无刷空心杯定子绕线工装及制作方法,其中绕线工装包括线架、线圈挡板和芯棒,所述芯棒两端的外壁四周对称分布有内孔,并且两端相对应的两个内孔处于同一竖直线上,所述线架的一端可插拔的插入在内孔内,并且上下一一对应设置,所述线圈挡板的两端设有穿孔,线圈挡板通过穿孔设置在线架上,且线圈挡板与芯棒之间留有用于绕线的绕线空间,其中芯棒的一端还设有凸台,在该凸台的四周侧壁上开设有用于三相引线穿过的引线槽。本发明大大节省了绕线时间,每相的线圈都未交叉重叠,比常规直流无刷空心杯电机的效率高；可以通过改变工装的结构实现多极数绕线,解决了不同槽极比绕线的困难,还能实现绕组星型接法。(The invention discloses a high-efficiency direct-current brushless coreless stator winding tool and a manufacturing method thereof, wherein the winding tool comprises a wire frame, a coil baffle and a core rod, inner holes are symmetrically distributed on the periphery of the outer walls of two ends of the core rod, two inner holes corresponding to the two ends are positioned on the same vertical line, one end of the wire frame can be inserted into the inner holes in a pluggable mode and is arranged in a one-to-one correspondence mode from top to bottom, two ends of the coil baffle are provided with through holes, the coil baffle is arranged on the wire frame through the through holes, a winding space for winding is reserved between the coil baffle and the core rod, one end of the core rod is also provided with a boss, and the peripheral side wall of the boss is provided with a lead slot for a three-phase lead to pass through. The invention greatly saves the winding time, and the coils of each phase are not crossed and overlapped, thereby having higher efficiency than the conventional DC brushless coreless motor; can realize the multipolar winding through the structure that changes the frock, solve the difficult of different slot pole than the wire winding, can also realize winding star type connection.)

1. The utility model provides a brushless coreless stator wire winding frock of high efficiency direct current, its characterized in that, includes line frame, coil baffle and plug, the outer wall at plug both ends all around the symmetric distribution have the hole to two corresponding holes in both ends are in same vertical line, the one end of line frame is inserted including downthehole to upper and lower one-to-one sets up, the both ends of coil baffle are equipped with the perforation, and the coil baffle runs through the setting on line frame through the perforation, and leaves the wire winding space that is used for the wire winding between coil baffle and the plug.

2. The high-efficiency brushless DC coreless stator winding tool according to claim 1, wherein a boss is provided at one end of the core rod, and a lead slot for a coil lead to pass through is provided on a peripheral side wall of the boss.

3. The high efficiency dc brushless coreless stator winding tooling of claim 1, wherein the removable wire rack is removably disposed within the bore.

4. The high efficiency dc brushless coreless stator winding tooling of claim 1, wherein the bobbin is made of metal or plastic.

5. The high efficiency dc brushless coreless stator winding tooling of claim 1, wherein the coil baffle is removably connected to the bobbin.

6. The high-efficiency brushless DC coreless stator winding tool according to claim 1, further comprising an insulating tape for winding a stationary coil.

7. The high-efficiency brushless DC coreless stator winding tool according to claim 1, further comprising a stator shaping tool for ensuring roundness of the coil and concentricity of the coil and the stator core, wherein the stator shaping tool comprises a positioning column and a positioning groove, and a positioning step is arranged in the positioning groove.

8. A method for manufacturing a high-efficiency direct-current brushless coreless stator is characterized in that the winding tool of any one of claims 1 to 7 is adopted for manufacturing, and the specific manufacturing method comprises the following steps:

firstly, sequentially inserting a wire frame into an inner hole of a core rod, and then fixing a coil baffle on the wire frame;

winding in a winding space between the coil baffle and the core rod by using a winding machine;

taking the coil baffle plate out after the coil is wound, taking the coil take-off frame down, winding an insulating adhesive tape on the outer circular surface of the coil, and taking the coil down;

placing the coil into a stator shaping tool and a stator iron core, ensuring the roundness of the coil by using the stator shaping tool and ensuring the concentricity of the coil and the stator iron core;

and fifthly, fixing the coil and the stator core by adopting glue such as anaerobic glue or epoxy glue, taking out the stator shaping tool after the glue is cured, and finishing the high-efficiency direct-current brushless coreless stator.

Technical Field

The invention relates to a high-efficiency direct-current brushless coreless stator winding tool and a manufacturing method, and belongs to the field of motor production and manufacturing.

Background

The application field of the direct-current brushless coreless motor is more and more extensive at present, and the requirements on the performance and the manufacturing process of the coreless motor are higher and higher. At present, the production process of the direct current brushless coreless motor at home and abroad is more complex, and particularly the production automation degree is far inferior to that of a toothed iron core motor in the processes of winding and stator assembly. At present, the coil is in a circle winding type after winding, the design can cause that the coil and the coil are overlapped to cause low efficiency, and the manufacture of a multi-pole motor is not facilitated, so that the difficulty of the manufacture process of the multi-pole motor is increased.

Meanwhile, the existing brushless DC coreless motor is wound by a customized winding machine, a high-precision winding tool is required, after the winding is finished, the winding needs to be rounded and then shaped by the tool, and finally the stator core is fixed by glue, so that the whole process has high requirements on the process.

In summary, the current production process of the brushless DC coreless motor has the following defects:

(1) the winding tool needs to be customized; the design is not beneficial to the diversification of the windings, and relatively complex tools need to be replaced as long as the lengths of the windings are different;

(2) the mode of the rolling and forming can lead the windings of all phases to be mutually overlapped, thus being not beneficial to the maximum exertion of the motor efficiency;

(3) at present, the winding mode is widely applied to a motor with 3 slots and one pair of poles, but the winding mode is not easy to manufacture for a motor with a plurality of poles and a plurality of slots;

(4) at present, the coil is mostly connected in a triangular mode, and compared with the conventional star-type connection, the current is large.

Disclosure of Invention

The invention aims to provide a high-efficiency direct-current brushless coreless stator winding tool and a winding method, which change the traditional direct-current brushless coreless winding mode, combine the iron core winding mode to enable the coreless motor to be convenient and feasible for winding, and can replace fewer winding tools for different winding lengths, thereby greatly saving the winding time; the coils of each phase are not crossed and overlapped, and the efficiency is higher than that of a conventional direct-current brushless coreless motor; can realize the multipolar winding through the structure that changes the frock, solve the difficult of different slot pole than the wire winding, can also realize winding star type connection.

One of the technical schemes adopted by the invention is as follows: the utility model provides a brushless coreless stator wire winding frock of high efficiency direct current, its includes line frame, coil baffle and plug, the outer wall at plug both ends all around the symmetric distribution have the hole to two corresponding holes in both ends are in on same vertical line, the one end of line frame is inserted downthehole including to upper and lower one-to-one sets up, the both ends of coil baffle are equipped with the perforation, and the coil baffle runs through the setting on line frame through the perforation, and leaves the wire winding space that is used for the wire winding between coil baffle and the plug.

Furthermore, one end of the core rod is provided with a boss, and the side wall around the boss is provided with a lead slot for a coil lead to pass through.

Furthermore, the wire frame can be movably arranged in the inner hole in a pluggable manner; and the wire frame is made of metal or plastic.

Furthermore, the coil baffle is movably connected with the coil holder in a pluggable mode.

Further, the tool further comprises an insulating adhesive tape used for winding and fixing the coil.

Further, the tool also comprises a stator shaping tool for ensuring the roundness of the coil and the assembly concentricity of the coil and the stator core; the stator shaping tool comprises a positioning column and a positioning groove, and a positioning step is arranged in the positioning groove.

The second technical scheme adopted by the invention is as follows: a method for manufacturing a high-efficiency direct-current brushless coreless stator adopts a winding tool in the first scheme for manufacturing, and specifically comprises the following steps:

firstly, sequentially inserting a wire frame into an inner hole of a core rod, and then fixing a coil baffle on the wire frame;

winding in a winding space between the coil baffle and the core rod by using a winding machine;

taking the coil baffle plate out after the coil is wound, taking the coil take-off frame down, winding an insulating adhesive tape on the outer circular surface of the coil, and taking the coil down;

placing the coil into a stator shaping tool and a stator iron core, ensuring the roundness of the coil by using the stator shaping tool and ensuring the concentricity of the coil and the stator iron core;

and fifthly, fixing the coil and the stator core by adopting glue such as anaerobic glue or epoxy glue, taking out the stator shaping tool after the glue is cured, and finishing the high-efficiency direct-current brushless coreless stator.

The invention has the beneficial effects that: the invention changes the traditional winding mode of the direct current brushless coreless coil, the coil is not rolled after the coil is wound, but the coil is directly wound on the tool, the whole coil does not have a cross overlapping part after shaping, the utilization rate of the coil is improved, and the efficiency of the motor is improved; the steps of coiling and the like are not needed after the winding is finished, so that the production process can be simplified, and the labor cost is saved; in addition, the invention can realize the winding manufacture of the multi-slot multi-pole motor, is not limited to the traditional 1-pair-pole motor and can be suitable for different rotating speed ranges; the traditional winding mode is a triangular connection method, but the invention can be suitable for star connection and triangular connection, and the current of the star connection method under the same power is only 0.577 times of that of the triangular connection method.

Additional aspects and advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.

Drawings

FIG. 1 is a schematic structural diagram of a DC brushless coreless stator winding tool;

FIG. 2 is a schematic structural view of a coil baffle;

FIG. 3 is a schematic view of the structure of the mandrel;

FIG. 4 is a schematic structural diagram of a stator shaping tool;

FIG. 5 is a schematic view of the coil after the wire is wound;

fig. 6 is a schematic view of the assembly of the coil and the stator core after wire winding.

Labeled as: 1-coil holder, 2-coil baffle, 21-perforation, 3-core rod, 31-inner hole, 32-boss, 33-lead slot, 4-coil, 5-insulating tape, 6-stator shaping tool and 7-stator iron core.

Detailed Description

The invention is described in detail below with reference to the figures and specific embodiments.

As shown in fig. 1 to 5, a high-efficiency dc brushless coreless stator winding tool includes a bobbin 1, a coil baffle 2 and a core rod 3, inner holes 31 are symmetrically distributed around the outer wall of two ends of the core rod 3, two inner holes 32 corresponding to the two ends are located on the same vertical line, one end of the bobbin 2 is inserted into the inner hole 31 in a pluggable manner, and is arranged in a one-to-one correspondence manner from top to bottom, through holes 21 are formed in two ends of the coil baffle 2, the coil baffle 2 is movably arranged on the bobbin 1 in a pluggable manner through the through holes 21, and a winding space for winding is left between the coil baffle 2 and the core rod 3, wherein one end of the core rod 3 is further provided with a boss 32, and a lead groove 33 for a three-phase lead to pass through is formed in the peripheral side wall of the boss 32.

The specific implementation process of manufacturing the coreless stator by utilizing the direct-current brushless coreless stator winding tool comprises the following steps:

(1) the material of the bobbin 1 can be metal or plastic, and the number of the bobbins 1 is determined by the number of the stator slots. Before winding, the wire frame 1 is sequentially inserted into the inner hole 31 of the core rod 3, then the coil baffle 2 is fixed on the wire frame 1, so that the whole tool can be put into a winding machine for winding after being assembled, the tool is simple and convenient to mount in the whole process, the stator winding with the multi-pole number and the multi-slot number can be realized, and for example, 12 wire frames 1 are needed only from top to bottom for a 6-slot 4-pole motor. After the winding is finished, the coil baffle 2 is taken out, the coil holder 1 is taken down, the insulating adhesive tape 5 is wound on the outer circular surface of the coil 4, then the coil 4 is taken down, the wound coil is shown in a figure 4, the coils do not overlap with one another, the utilization rate of the winding can be improved, and the motor efficiency is higher than that of a conventional direct-current brushless coreless motor.

(2) The wound coil 4 is placed into a stator shaping tool 6 and is placed into a stator iron core 7, the stator shaping tool comprises a positioning column and a positioning groove, a positioning step is arranged in the positioning groove, the stator shaping tool 6 can well guarantee the roundness of the coil 4, and meanwhile the concentricity of the coil 4 and the stator iron core 7 is guaranteed; the coil 4 and the stator core 7 can be fixed by glue such as anaerobic glue or epoxy glue, and the stator shaping tool 6 is taken out after the glue is cured, so that the high-efficiency direct-current brushless coreless stator is completed.

The foregoing illustrates and describes the principles, general features, and advantages of the present invention. It should be understood by those skilled in the art that the above embodiments do not limit the scope of the present invention in any way, and all technical solutions obtained by using equivalent substitution methods fall within the scope of the present invention.

The parts not involved in the present invention are the same as or can be implemented using the prior art.