阅读说明：本技术 用于电机的单线无三相并接断头绕线工艺及其应用的电机 (Single-wire three-phase-free splicing and splicing winding process for motor and motor applied by same ) 是由 李玉刚 刘亚军 卜言柱 胡宜豹 胡金龙 程兴 李升� 张力 周建华 周维 刘竹园 于 2021-08-02 设计创作，主要内容包括：本发明公开了一种用于电机的单线无三相并接断头绕线工艺及其应用的电机,通过自动绕线设备对定子齿根据预设的三相绕组目标进行单线绕设,自动绕线设备的绕线机械臂采用控制器进行驱动控制,当绕设至需要对相邻不同相绕组并接输出的位置时,绕线机械臂将其所对应的单相绕组向定子外侧延伸后,通过弯折返回定子内侧继续对定子齿进行与延伸前绕组相不同的单相绕组绕设,将向定子外侧延伸的绕组弯折点作为单相绕组的无断点接头输出点；本发明不仅避免了三相并接时进行断头连接所耗费的工序时间以及所产生的废线,而且无需设置附加防护固定装置,显著节约了电机绕组成本,同时提出的绕线工艺快速便捷,提高了单线无三相并接断头绕线工艺的实施效率。(The invention discloses a single-wire three-phase-free splicing and breaking winding process for a motor and a motor applied by the same, wherein single-wire winding is carried out on stator teeth according to a preset three-phase winding target through automatic winding equipment, a winding mechanical arm of the automatic winding equipment adopts a controller for driving control, when the winding mechanical arm is wound to a position where adjacent different-phase windings are required to be spliced and output, the winding mechanical arm extends the corresponding single-phase winding to the outer side of a stator, then returns to the inner side of the stator through bending and continues to wind the single-phase winding different from the winding before extension on the stator teeth, and a winding bending point extending to the outer side of the stator is used as a non-breaking-point joint output point of the single-phase winding; the invention not only avoids the process time consumed by broken connection when three phases are connected in parallel and the waste wire generated, but also does not need to arrange an additional protection fixing device, thereby obviously saving the cost of the motor winding, simultaneously, the proposed winding process is quick and convenient, and the implementation efficiency of the single-wire three-phase-free broken-connection winding process is improved.)

1. A single-wire non-three-phase splice-free winding process for a motor comprises a stator and a permanent magnet rotor which are installed into a whole in a magnetic coupling mode, wherein the stator is provided with a plurality of stator teeth which are distributed at intervals on the circumference, and winding grooves are formed between adjacent stator teeth; the winding mechanical arm of the automatic winding equipment is driven and controlled by a controller, when the winding mechanical arm is wound to a position where adjacent different-phase windings are required to be connected in parallel for output, the winding mechanical arm extends the corresponding single-phase winding to the outer side of the stator, then the winding mechanical arm returns to the inner side of the stator through bending to continue winding the single-phase winding different from the winding before extension on the stator teeth, and the winding bending point extending to the outer side of the stator is used as a breakpoint-free joint output point of the single-phase winding.

2. The single-wire three-phase-free splice winding process as claimed in claim 1, wherein said automatic winding equipment effects said bending by hooking a winding extending outside the stator by a hooking arm.

3. A single-wire three-phase-free and break-joint winding process as claimed in claim 1, wherein the winding is made of enameled wire, and the insulation layer at the bending point of the winding is removed by stripping or melting or corrosion to realize break-joint-free joint output.

4. The single-wire three-phase-free and splice-joint winding process according to claim 1, wherein the motor is composed of 1 or more motor basic units, each motor basic unit is driven to run by adopting an independent control signal, no angular difference exists between the motor basic units, the number of pole pairs in a single motor basic unit and the number of winding slots adopt a mutual prime number relationship, and the number of pole pairs in a single winding basic unit and the number of winding slots adopt a mutual prime number relationship.

5. The single-wire three-phase-free and break-point joint winding process as claimed in claim 1, wherein when a plurality of motor basic units are adopted by the motor, break-point-free joint output points of the motor basic units of the same winding phase are connected in parallel for output.

6. A single wire three-phase-less and break-point terminal winding process as claimed in claim 5, wherein the electrical connection to the break-point-less terminal output points of the motor base units of the same winding phase is made through external connection wires.

7. The single-wire three-phase-free and break-point winding process of claim 4, wherein the number of break-point-free point connector output points per phase winding in each motor base unit is 1.

8. The single wire three-phase-less splice winding process of claim 1 wherein the automatic winding apparatus comprises a winding robot arm and a hook arm; the winding machine mechanical arm comprises a wire inlet nozzle and a wire winding nozzle which are respectively installed on the wire winding arm, the wire winding arm is driven by a controller, the wire winding arm drives the wire winding nozzle to drive a winding to extend to the outer side of the stator, and the wire hooking arm is used for hooking a wire to the extended winding in a limiting mode and achieving the bending effect.

9. An electrical machine, characterized in that it employs a single-wire, three-phase-less and splice-off winding process as claimed in any one of claims 1 to 8.

10. The motor of claim 9, wherein the motor is a permanent magnet synchronous motor for use in a two-wheeled or three-wheeled electric vehicle.

Technical Field

The invention belongs to the field of motor winding design, and particularly relates to a single-wire three-phase-free and broken-end-connection-free winding process for a motor.

Background

In order to improve the slot filling rate of the motor winding, the applicant proposes a winding basic unit design with a specific layer number distribution on line (see CN113036971A and the prior application with application number 202110681900.7), and completes winding of the winding by using a single wire. However, after further popularization, the applicant finds that, because of the adoption of a single-wire winding, the winding needs to be disconnected and then the windings of the phases are welded in parallel, a large number of winding joints (usually adopting a star connection method of connecting three phases in parallel) inevitably occur, the joints not only consume a large number of processes, but also cause a large number of broken ends and waste wires, and meanwhile, a protection fixing device needs to be prepared for each winding joint additionally, so that the manufacturing cost is increased, and the structure is not favorable for aesthetic appearance; specifically, see fig. 3 and 4 respectively, which show a single-wire motor winding structure having 2 motor basic units and 4 motor basic units, wherein the single-wire motor winding of the 2 motor basic units shown in fig. 3 needs to make 2 three phases ((including U-phase, V-phase, and W-phase) and connected with a1 and a2 (at least 6 breakouts need to be made), the single-wire motor winding of the 4 motor basic units shown in fig. 4 needs to make 4 three phases and connected with b1, b2, b3, and b4 (at least 12 breakouts need to be made), and when the number of the motor basic units is larger, the number of the required three-phase and connected breakouts is larger.

In order to solve the technical problem, the applicant searches the jointless winding technology, and finds that the utility model with the publication number of CN2896668Y discloses a straight line oil pumping motor jointless winding process device, wherein an oil pumping motor stator is horizontally installed on a rotating bracket, a mandrel of the oil pumping motor stator is connected with a main shaft of a speed reducing motor through a transmission pair, a pair of follow-up hanging racks are installed at the initial position of a plurality of groups of three-phase coils in the radial direction, one phase of the mandrel is installed on a bobbin bracket beside the straight line, and the other two phase of the bobbin is installed on the follow-up hanging rack at the initial position of the stator. When the three-phase winding coil of the oil pumping motor stator is wound, the wire end does not need to be cut off and another phase coil is wound after one phase coil is wound, and finally, the joints of the same-phase coils of all groups are welded and other auxiliary works are carried out to realize a plurality of groups of three-phase winding coils, each group of coils of each phase is only one winding, but the applied stator structure and the winding structure thereof are obviously different from the conventional motor structure and cannot be applied to the conventional field; the invention patent with publication number CN104617721A discloses a method for preparing stator winding of high-efficiency ac motor, which includes winding, threading and inserting processes. The winding process comprises the following steps: each phase U, V, W has six coils U1, U2, U3, U4, V1, V2, V3, V4, W1, W2, W3 and W4, wherein 6 coils of each phase are continuously wound, the winding directions of the wound coils are consistent, and no joint exists between 6 coils of each phase; w1, W3, V2, V4, U2 and U4 all comprise 2 large coils, the span of each large coil is 1-9 slots, W2, W4, V1, V3, U1 and U3 are 1 small coil, and the span is 1-8 slots. The threading process is after the winding process and before the coil inserting process, the threading process has the effect of enabling the winding directions of the large coil and the small coil of each phase to be opposite, and the scheme adopts multiple groups of parallel winding and is obviously not suitable for the single-wire winding process.

Based on the research experience of the present inventors in this field for many years, the present applicant hoped to seek a technical solution to solve the above technical problem.

Disclosure of Invention

In view of the above, the present invention provides a single-wire no-three-phase parallel-connection-disconnection winding process for a motor and a motor using the same, which not only avoids the process time consumed by disconnection connection when three phases are connected in parallel and the waste wire generated, but also does not need to provide an additional protection fixing device, thereby significantly saving the cost of the motor winding, and the proposed winding process is fast and convenient, significantly improves the implementation efficiency of the single-wire no-three-phase parallel-connection-disconnection winding process, and is very suitable for scale popularization and implementation.

The technical scheme of the invention is as follows:

a single-wire no-three-phase and break-joint winding process for a motor comprises a stator and a permanent magnet rotor which are installed into a whole through magnetic coupling, the stator is provided with a plurality of stator teeth which are distributed at intervals on the circumference, winding slots are formed between adjacent stator teeth, the winding process is characterized in that the stator teeth are wound by single wire according to a preset three-phase winding target through automatic winding equipment, wherein the three-phase winding adopts a delta connection method, a winding mechanical arm of the automatic winding equipment adopts a controller to carry out drive control, when the winding machine is wound to a position where adjacent different-phase windings are required to be connected in parallel for output, after the winding machine mechanical arm extends the corresponding single-phase winding to the outer side of the stator, and the winding bending point extending towards the outer side of the stator is used as a non-breakpoint joint output point of the single-phase winding. Under the condition that each winding slot has the same number of turns of windings, the motor speed of the conventional star-connection winding (output winding with multi-break-point joints) is adopted as 1.732.

Preferably, the automatic winding equipment is used for hooking and limiting the winding extending towards the outer side of the stator through a hooking arm, so that the bending effect is realized.

Preferably, the winding is made of enameled wires, and the insulation layer at the bending point of the winding is removed through stripping or melting or corrosion, so that the output of the breakpoint-free joint is realized.

Preferably, the motor is composed of 1 or more motor basic units, each motor basic unit respectively adopts an independent control signal to realize driving operation, and no angle difference exists between the motor basic units; the number of pole pairs and the number of winding slots in a single motor basic unit adopt a mutual prime number relationship, and the number of pole pairs and the number of winding slots in a single winding basic unit adopt a mutual prime number relationship.

Preferably, when the motor adopts a plurality of motor basic units, the output points of the non-breakpoint connectors of the motor basic units of the same winding phase are connected in parallel for output.

Preferably, the motor base units are electrically connected with the no-break-point connector output points of the motor base units of the same winding phase through external connecting wires.

Preferably, the number of the output points of the no-break-point connector of each phase winding in each motor basic unit is 1.

Preferably, the automatic winding equipment comprises a winding mechanical arm and a wire hooking arm; the winding machine mechanical arm comprises a wire inlet nozzle and a wire winding nozzle which are respectively installed on the wire winding arm, the wire winding arm is driven by a controller, the wire winding arm drives the wire winding nozzle to drive a winding to extend to the outer side of the stator, and the wire hooking arm is used for hooking a wire to the extended winding in a limiting mode and achieving the bending effect.

Preferably, the motor adopts the single-wire three-phase-free and broken-end winding process.

Preferably, the motor is a permanent magnet synchronous motor and is applied to two-wheeled or three-wheeled electric vehicles.

The utility model provides a extend the winding to the stator outside and buckle formation no breakpoint and connect the output point, it buckles to extend the winding to the stator outside to carry out single line winding the in-process of establishing specifically to collude the line arm through coiling machine arm combination, and set up the winding that the winding corresponds around buckling into inequality mutually, and then realize three-phase winding's output connection, the winding structure that has many broken ends tie point when can directly replace the three-phase and connect, the process time that not only has avoided the three-phase to connect and has consumeed and produced waste wire when connecting, and need not to set up additional protection fixing device, it costs to show to have practiced thrift motor winding, the winding technology that this application provided simultaneously is quick convenient, it does not have the three-phase and connects the implementation efficiency of broken ends winding technology to show to have improved the single line, be particularly suitable for carrying out the scale popularization and implementation.

Drawings

Fig. 1 is a schematic view of a stator structure (windings are not shown) in embodiment 1 of the present application;

fig. 2 is a schematic diagram of a single-wire breakpoint-free joint winding structure in embodiment 1 of the present application;

fig. 3 is a schematic diagram of a conventional single-wire winding structure (2 motor base units) as described in the background of the present application;

FIG. 4 is a schematic diagram of a conventional single-wire winding configuration (4 motor base units) as described in the background of the present application;

fig. 5 is a schematic diagram of a single-wire breakpoint-free joint winding structure in embodiment 2 of the present application;

fig. 6 is a schematic diagram of a single-wire no-break-point connector winding structure in embodiment 3 of the present application.

Detailed Description

The embodiment of the invention discloses a single-wire no-three-phase splice-free winding process for a motor, wherein the motor comprises a stator and a permanent magnet rotor which are installed into a whole in a magnetic coupling mode, the stator is provided with a plurality of stator teeth which are distributed at intervals on the circumference, winding grooves are formed between every two adjacent stator teeth, the winding process is used for winding the stator teeth on a single wire according to a preset three-phase winding target through automatic winding equipment, and the three-phase winding adopts a triangular connection method; the winding mechanical arm of the automatic winding equipment is driven and controlled by the controller, when the winding mechanical arm is wound to a position where adjacent different-phase windings are required to be connected in parallel for output, the winding mechanical arm extends the corresponding single-phase winding to the outer side of the stator, then the winding mechanical arm returns to the inner side of the stator through bending to continue winding the single-phase windings different from the windings before extension on the stator teeth, and the winding bending point extending to the outer side of the stator is used as a breakpoint-free joint output point of the single-phase windings.

In order to make those skilled in the art better understand the technical solution of the present invention, the technical solution in the embodiment of the present invention will be clearly and completely described below with reference to the drawings in the embodiment of the present invention, and it is obvious that the described embodiment is only a part of the embodiment of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

Example 1: a kind of electrical machinery, the electrical machinery adopts the synchronous electrical machinery of permanent magnetism, can be applied to two-wheeled or three-wheeled electric motor car according to the actual need, in this embodiment, the synchronous electrical machinery of permanent magnetism includes stator 1 and permanent magnet rotor that the magnetic coupling is installed as an organic whole, the stator 1 is installed on stator mounting bracket 2, the stator 1 has several stator teeth 11 that are distributed in the form of circumference interval, form the winding slot 12 between the adjacent stator tooth 11, specifically, please refer to fig. 1, in this embodiment, the electrical machinery adopts the winding slot 12 of 48 antipoles 26, that is, the quantity of the stator tooth 11 is 48, naturally, can also adopt the electrical machinery of other specifications; preferably, in order to further improve the driving effect of the motor, in the present embodiment, the span coefficient of the motor is 1; the span coefficient is a positive integer which is the same as or closest to the ratio of the number of winding slots to the number of poles; specifically, for example, 5 pairs of pole 12 winding slots, 14 pairs of pole 24 winding slots, 13 pairs of pole 24 winding slots, 16 pairs of pole 36 winding slots, 30 pairs of pole 54 winding slots, or 40 pairs of pole 72 winding slots are preferably used, and the present embodiment is not limited uniquely;

referring to fig. 2, in the present embodiment, a stator 1 performs winding of a three-phase winding by using a single-wire three-phase-free and end-broken winding process, in which an automatic winding apparatus performs single-wire winding on stator teeth 11 according to a preset three-phase winding (including U-phase, V-phase, and W-phase) target, and the three-phase winding target is set to be delta connection; the winding mechanical arm of the automatic winding equipment adopts a controller to carry out driving control, when the winding mechanical arm is wound to a position where adjacent windings of different phases are required to be connected in parallel for output, the winding mechanical arm extends the corresponding single-phase winding to the outer side of the stator, then the winding mechanical arm returns to the inner side of the stator 1 through bending to continue winding the single-phase winding different from the winding before extension on the stator teeth, and the winding bending points extending to the outer side of the stator 1 are used as the breakpoint-free joint output points c1, c2 and c3 of the single-phase winding; specifically, in this embodiment, the automatic winding device may adopt a known structure of the automatic winding device, as long as the driving scheme required by the winding process scheme required in this embodiment is input and stored in the controller in advance, so as to ensure that the automatic winding device performs driving control according to the predetermined target winding process scheme, and as for the remaining related structures of the automatic winding device, this embodiment is not particularly limited, and these are all routine technical choices that can be made by those skilled in the art based on the scheme described in this application; preferably, the automatic winding equipment comprises a winding mechanical arm and a wire hooking arm; the winding mechanical arm comprises a wire inlet nozzle and a wire winding nozzle which are respectively installed on the wire winding arm, the wire winding arm is driven and controlled by a controller, the wire winding nozzle drives a winding to extend to the outer side of the stator to the wire hooking arm by controlling and driving the wire winding arm, the wire hooking arm is used for performing wire hooking limiting on the winding extending to the outer side of the stator, the effect of bending the extended winding is achieved, the whole operation process is convenient and efficient, and a three-phase parallel-connection broken-end connection output structure in a conventional motor winding is directly avoided; preferably, in the present embodiment, in the process of winding the single wire, the length of the winding mechanical arm that needs to extend the winding at the target position to the outside may be preset according to the actual specification of the stator, and this embodiment is not particularly limited; preferably, the winding is an enameled copper wire in the embodiment, and the wire diameter of the enameled copper wire is preferably in the range of 0.7-1.3 mm; in the embodiment, after winding, the insulation layer at the winding bending point (i.e. the insulation coating protective layer of the enameled copper wire) can be removed by stripping, melting or corroding, so that the joint output without the three-phase parallel connection point is realized; it should be noted that, for practical fast connection of the windings, the connection between the winding phases according to the present embodiment may still adopt a breakpoint connection process as required.

Preferably, in this embodiment, the motor is composed of 1 motor basic unit, and in other embodiments, it is of course possible to adopt a plurality of motor basic units, specifically, see example 2 and example 3; the number of the output points of the non-breakpoint connector of each phase winding in each motor basic unit is 1.

Under the condition that each winding slot has the same number of turns of windings and the same number of motor units, the motor speed of the embodiment is 1.732, which adopts the motor speed of the conventional star connection method (with a plurality of winding joints), and the motor speed is in a proportional relation with the number of the parallel motor units; the motor speed of the present embodiment 1 is close to the conventional motor speed with the motor winding shown in fig. 3.

Example 2: the other technical solutions of this embodiment 2 are the same as those of embodiment 1, except that, in this embodiment 2, please refer to fig. 5, the motor is composed of 2 motor basic units, each motor basic unit respectively adopts an independent control signal to implement driving operation, and there is no angular difference between the motor basic units, in order to further improve the driving efficiency of the motor, in this embodiment, the number of pole pairs in a single motor basic unit and the number of winding slots adopt a mutual prime number relationship, and the number of pole pairs in a single winding basic unit and the number of winding slots adopt a mutual prime number relationship; compared with the related scheme adopting non-mutual prime number relationship, the embodiment has more excellent driving performance;

in the present embodiment, the no-break-point connector output points (including d1, d2, d3, d4, d5 and d6) of the motor basic units of the same winding phase are connected in parallel and output, and preferably, in the present embodiment, the no-break-point connector output points are respectively and electrically connected with the no-break-point connector output points of the motor basic units of the same winding phase through external connecting wires (an enameled copper wire can be used as well), and a welding connection can be specifically adopted.

Example 3: the remaining technical solutions of this embodiment 3 are the same as those of embodiment 2, except that in this embodiment 3, the motor employs 30 pairs of poles 54 winding slots; referring to fig. 6, the motor is composed of 6 motor basic units; in the present embodiment, the no-break-point connector output points (including e1, d2, d3, d4, d5 and d6) of the motor basic units of the same winding phase are connected in parallel and output, and preferably, in the present embodiment, the no-break-point connector output points are respectively and electrically connected with the no-break-point connector output points of the motor basic units of the same winding phase through external connecting wires (an enameled copper wire can be used as well), and a welding connection can be specifically adopted.

Of course, based on the inventive concept of the present application, the present invention can also be applied to motors having other specifications of counter poles and winding slots, and other suitable numbers of motor basic units can also be adopted.

It should be further specifically noted that the single-wire no-break-point connector winding structure referred to in the present application can be prepared into a single-layer or multi-layer winding structure according to practical requirements, and can be specifically incorporated into the related prior patent applications of the present applicant (for example, publication No. CN113036971A and application No. 202110681900.7), which are conventional technical choices that can be made by those skilled in the art in conjunction with the present application. When a multilayer winding scheme is adopted, particularly when an (n +1) layer-n layer type winding distribution structure is applied, preferably, the permanent magnet rotor comprises a plurality of permanent magnet steel, the remanence Br of the permanent magnet steel is not less than 1.2T, and/or the coercive force HCj of the permanent magnet steel is not less than 15Koe, namely 15000Oe (oersted); the units of remanence Br are T (Tesla); the number of slots of each phase of winding in the stator is 2a, wherein a is a positive integer more than or equal to 1; through practical verification, the high-grade magnetic steel can achieve the similar effect of increasing the magnetic energy product of the motor, and the volume of the high-grade magnetic steel can be smaller than that of the conventional magnetic steel; when the motor with the same turning radius is adopted, the thickness of the magnetic steel can be obviously reduced: the thickness of the magnetic steel is reduced, the direct-axis magnetic resistance is reduced, the direct-axis inductance of the motor winding can be increased along with the reduction of the direct-axis magnetic resistance, the weak magnetic capacity of the motor is enhanced by the increase of the direct-axis inductance, and the energy loss of the motor in high-power weak magnetic can be greatly reduced; the motor stator with the (n +1) layer-n layer type winding distribution structure and the rotor with the high-grade permanent magnet steel are combined and applied, so that excellent weak magnetic speed expansion capability of a motor product is realized, the defect of fixed rotating speed of a single-wire winding motor is overcome, the motor product can flexibly meet different requirements at a subsequent application end through weak magnetic speed expansion, and the universality is greatly improved.

This embodiment creatively has proposed to extend the winding to the stator outside and has buckled formation no breakpoint and connect the output point, it is specifically carrying out the single line and extending the winding to the stator outside and buckle to carry out the in-process that the winding was established around buckling through the wire winding arm, and set up the winding that the winding corresponds around buckling as inequality, and then realize three-phase winding's output connection, can directly replace the three-phase winding structure that has many broken ends tie point when taking over, the process time that not only has avoided the three-phase to take over to carry out broken end connection when taking over and produced waste wire, and need not to set up additional protection fixing device, motor winding cost has been showing and practiced thrift, the winding technology that this embodiment provided is quick convenient simultaneously, the implementation efficiency that the single line does not have three-phase to take over and break the end winding technology is showing, be particularly suitable for carrying out the scale popularization and implementation.

It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.

Furthermore, it should be understood that although the present description refers to embodiments, not every embodiment may contain only a single embodiment, and such description is for clarity only, and those skilled in the art should integrate the description, and the embodiments may be combined as appropriate to form other embodiments understood by those skilled in the art.