Electric motor with multilayered rhomb-shaped windings

FIELD: electricity.

SUBSTANCE: present invention relates to electrical engineering, particularly to electric motors, with windings with an air core, and can be used in rotors of dc motors, as well as in stators of electronic-commuted (EC) motors. The electric motor contains a winding with an air core, made from several separate windings, made from conductors. The separate windings are superimposed on each other and have such a shape that there is shifting in the region of at least two opposite corners. According to the first version of the invention, half the sides of the separate windings is in an inner hollow cylinder, and the other half is in an outer hollow cylinder without overlapping the inner hollow cylinder. According to the second version, half of the sides of separate windings is in a first plane, and the other in a second plane, without overlapping the first plane. The overlapping separate windings together form a flat winding, which comprises a first plane and a second plane. The separate windings are provided with an extra amount of conductor material as allowance in the shifting region, which forms preferably a U-shaped or loop-shaped bulge on the inner contour of the separate windings.

EFFECT: lower costs and easier assembly of windings with an air core for electric motors.

16 cl, 9 dwg

The present invention relates to an electric motor having a coil with an air core, made up of many separate windings, made of conductors, in which the individual windings are superimposed one on another lap.

The present invention particularly relates to a coil with an air core is used as the rotor of the DC motors and stators for electronically-commutated (EC) motors.

Like most electric motors described herein motors mainly can be designed as a rotating motors or linear motors. In this case, a separate winding impose on one another lapped flat or curved; instead of a circuit for the formation of symmetrical hollow cylinder they have front and rear ends in the direction of motion. A linear motor that specifies the rectilinear direction of movement, is mostly a result of the cylindrical projection of the rotating engine. The radial coordinate is projected onto a Cartesian coordinates perpendicular to the direction of motion, tangential coordinate or the angular coordinate is projected onto a Cartesian coordinates in the moving direction, and the axial coordinate is projected onto a Cartesian coordinate perpendicular to the other two above. The term qi is indijskie coordinates will be used in the future in the same way and at the same time to determine the appropriate Cartesian coordinates in the projection.

Separate coils according to the prior art are usually made of a wire having, in addition to the insulation layer, providing a bonding or sintering. Due to this, the manufacturing process could also consist of several separate steps without the need to provide mechanical coupling between the individual windings.

Cylindrical winding for electrical machines known in the prior developments, for example in DE 1538843 A1, where the windings are made of wire and stretched in order to give them a diamond shape.

A method of manufacturing such a cylindrical windings for electrical machines is known from DE 1801263 A1.

Such windings are used as the rotor of a small DC motors with permanent excitation, and the stator of electronically commutated electric motors.

Mechanically commutated DC motors having similar windings, referred to also as motors having rotors with no core, electric motors with conical rotors or asynchronous motors with Cup-shaped and hollow rotor. Appropriate electronic commutated motors are referred to as engines, having a coil with an air core, or aspatame engines/motors with Keyless start.

These engines are appreciated and Shire is to apply due to their high efficiency, there is no time to stop and linear starting characteristics (open circuit and/or closed circuit).

Linear motors with appropriate structure, also known from the prior art. On previous developments also known electric motors with windings made of cylinders with a single winding.

The object of the present invention are electric motors with improved electrical and mechanical symmetry and higher performance. In addition, the subject of the present invention is to achieve a higher degree of automation of the production process is similar to the electric motors.

One universal solution to this problem lies in the preliminary formation of separate windings in such a way as to create an offset in at least two opposite corners, so that one half of the parties were located in the same plane and half of the parties were located in another plane.

In a particular embodiment that may mean that each individual winding is radially different plane relative to the respective other party on the same axial height, so you can separate winding to place one above the other overlap. Optionally, these planes are curved and have Qili the shape form. This change of plane hereinafter referred to as offset.

To implement the overlap must offset at least in the region of two opposite corners of the individual windings in the region of the longitudinal ends of the winding. This area of the longitudinal ends of the winding hereinafter referred to as the neutral zone.

By placing overlapping optimum use of space winding. In turn, this leads to the optimization of power density. Another advantage realized by the solution according to the present invention is that a separate windings mutually equalize each other, which leads to improved symmetry. In DC motors, and electrically switched engines is improved electric symmetry, which consequently promotes smoother and with less loss of the engine. In DC motors this has another advantage - lower imbalance and greater uniformity of rotation of the rotor. Furthermore, the design offers a simple way to automate the manufacture of the winding. A preferential embodiment of the electric motor are further explained in the dependent claims.

In the preferred embodiment a separate winding, priee consideration in expanded form, laid in a spiral around an axis which, when the coil is in the collapsed state, extends in the radial direction, so that the conductors in the neutral zone were located almost tangentially. This embodiment will hereinafter be called concentric embodiment. As a separate winding in the coil do not overlap in this area, the offset in this area can be made optional on the curve.

This embodiment allows a particularly convenient way to perform a parallel winding multiple conductors so that they are parallel to the axis of coiling in the deployed coil and perpendicular to, the side-by-side to the rotational axis or, respectively, to the plane of motion in wound form. In the finished winding wires are wound in parallel, are connected electrically in parallel.

Another preferred embodiment consists in twisting or svidanie many isolated individual conductors to form a harness before the winding process, in which in the finished winding separate the wiring harness are connected electrically in parallel. Of course, can also be used and only one conductor to the coil.

If a separate winding is provided for the additional number of conductor as an allowance designed to offset, this is particularly useful is as an additional amount of wire needed for the implementation of bias, and because the presence of additional wires in this area prevents its excessive tension.

In one embodiment, such a allowance can conveniently realize, if you shape it in the form of a U-shaped or loop-shaped bulge of the inner contour of the winding, and both the inner and outer portions of the individual winding has a predetermined shape, because this produces a precise geometric circuit across the diagonal line and achieved the advantage of optimal space utilization and also self-alignment.

In another preferential embodiment of a separate winding is asymmetric in the sense that the individual winding, at least in the unfolded flat condition, is actually rectangular in shape with unequal long sides and/or the shape of a quadrilateral with two adjacent short sides of equal length and two adjacent long sides of equal length (the deltoid). Using the design of the individual windings, in the unfolded flat condition having a form of a rectangle with two adjacent short sides of equal length and two adjacent long sides of equal length, you can collect all the winding in such a way that all the individual windings are located next to each other closely. Although, if a separate winding is constructed symmetrical side located radially on the outside, provided with gaps, if the inner side of aspolozhena close to each other, the asymmetry of the parties may be designed such that in the finished winding and the outer side and the inner side are close to each other, so that was the exact geometric circuit across the diagonal line in both layers and advantage as the optimal use of space and levelling increased profitable way. For very thin-walled cylinders radii of the inner and outer layer of the subtle and the perfect shape is close to symmetric. For not curved linear motors the ideal form is symmetric.

In another preferred embodiment of the separate windings are provided with separate between the coils, in the ideal case, the adjacent diagonal sections, in the ideal case, in a Central axial position, characterized by lower slope section, passing, in the ideal case, parallel to the axis, with the specified cross-section forms, in the ideal case, the hexagon. So, in engines with elongated windings can achieve a higher power density. The Central section can be straight or slightly tilted. Slightly tilted design has an effective influence on the stability of the winding compared to fully direct the embodiment, since the winding due to this offset or twisted in this hour is I.

In another preferred embodiment a separate winding is wound, in expanded form, around an axis which is in a collapsed coil passes in the tangential direction so that the conductors in the neutral zone are almost radially, thus creating an offset.

Specific quadrangular or hexagonal shape is achieved subsequent longitudinal stretching.

The entire winding is made of separate windings, which creates an advantageous embodiment to obtain a more accurate position of the wire and designs. This embodiment, like the embodiment described above, and therefore, has a similarly positive effect on the symmetry, use of space and the possibilities for Assembly.

The winding is preferably made of individual wires or conductors, twisted/twisted in the harness, but may also be made of separate conductors laid parallel.

As an alternative to longitudinal tension, a separate coil may be formed in one embodiment so that in addition to the radial displacement at both ends of the winding it contains two additional offset in other points of the inversion. Under the points of inversion understand the areas in which the conductors change their direction.

If a single winding with a primary end in the Astok and final leaf area of single-layer or multi-layer conductor, forming a separate winding, with the primary end section and the terminating terminal site are out in the region of one of the corners of the individual windings, the power supply of the finished coil can be brought solely easily by traditional means.

To provide the necessary conductive connection between the individual windings, it is advantageous in one embodiment, especially for DC motors, if one initial end part of the first separate winding is connected to the final end part of the second separate winding for forming the connecting wires of the rotor. A corresponding embodiment can also be used to electronically-commutated motors.

The invention also relates to a method of manufacturing an electric motor containing a coil according to any one of claims device. The aim of the present invention there is also the achievement of a higher degree of automation of production and improving the quality of the winding.

Especially good contact with low cost can be achieved if the initial tail part of the layer of the first individual wire windings electrically connecting/twist-terminated end section adjacent individual windings, and the initial end part of the wire first individual amlodipinesee on the outer side of the second separate winding down to the final end portion of the second wire separate winding.

Also preferably, each of the conductors changed the plane on the lower and upper ends, respectively, passing perpendicular to the plane of projection. This will allow you to implement a quick and easy transition of conductors from one plane to another.

If the parties located outside in a collapsed coil, tilted more heavily than the hand inside in a collapsed coil, you can implement another preferred embodiment.

Below is a more detailed explanation of examples of embodiments of the present invention with the drawings. The drawings show:

figure 1 is a side view of a winding according to the invention with separate windings in a concentric form;

figure 2 schematically given a detailed view of the embodiment of the individual windings in a concentric form, but in the unfolded flat condition;

figure 3 is a detailed view of an embodiment of a separate winding in a distributed form in the unfolded flat condition;

figure 4 is a detailed view of another embodiment of a separate winding in a distributed form in the unfolded flat condition;

figure 5 shows two schematic diagrams of two other embodiments a separate winding in the unfolded flat condition, one with slightly beveled and one with straight lines;

figure 6 - schematic p is zestawienie location overlapping layers of several separate windings;

figure 7 is a detailed schematic partial view of two separate windings, layered overlapped, the initial and final end sections of the conductor, in which one completes the tail part of a separate winding is electrically connected to the starting end section of another individual winding; and

on Figa and 8b - axial projection views offset in two different examples of embodiments.

Figure 1 shows a side view of a winding 1 of the electric motor according to the present invention. Coil 1 includes a hollow cylindrical body. The hollow cylindrical winding body made up of many individual windings 2. Separate windings, thus alternating, stacked one above the other overlap. In figure 1 you can see one half of the individual windings 2, while the other half of the respective individual winding 2 is closed adjacent individual coil 2. One half of the individual winding 2 so located on the outer side of the winding 1, and the other half on the inner side of the winding 1. Coil 1 has a Central axis of symmetry 3, which is also the axis of rotation of the rotor's longitudinal axis. The symmetry of the internal structure of the winding is ideally axial symmetry. One half of the individual winding 2 has a smaller distance to assymmetry, than the other half of the individual winding 2. Thus, a separate winding has two different radius of curvature. Three wires 4 located radially above the other, form a single winding 2 in the form of concentric diamond-shaped configuration side by side. Three wires form the starting end section 5 and the terminating end section 6. Individual conductors 4 of the final end portion 6 of the first individual coil 2 are electrically connected with conductors 4 initial end portion 5 of the second separate windings 2 and form a connecting wire winding 7. The connecting wire 7 is clearly visible in figure 1 compared to the initial end sections 5 and trailing end sections 6 of the conductor 4. Primary end sections 5 and trailing end sections of the conductors 6 can best be seen in figure 2.

Also clearly visible that the individual winding 2 overlap overlap and that one half of the parties is located in the inner cylinder 16, while the other half of the parties is located in the outer cylinder 15, forming the offset. Half of the parties is located in the first plane 18, and the other half of the parties forming the offset 17 is parallel to the plane 19. Form a separate windings 2 is such that the individual windings 2 are formed on at least one section at m is re the one hand 9, 10, 11, 12 so that the outer edge of one of the winding 1 is in contact with the inner edge of the adjacent winding 1 so that the tangential freedom of movement separate winding 2 is limited by the geometric circuit. Inclined portion of the outer layer 9, and 10 higher than that of the inner layer 11 and 12.

Figure 2 presents a separate winding 2. In this embodiment a separate winding 2 on the side opposite the starting end section 5 and the final end section 6, provides for the allowance 8. This allowance 8 is formed as a U-shaped bulge.

According to the present invention, the allowance is provided in each place where a radial offset.

As shown in figure 2, the allowance 8 is also provided in the opposite corner of separate windings 2, that is, the part from which departs the initial end section 5 and the terminating end section 6. Allowance 8 required to complete the shift, shown in more detail in Fig.6. Two right-wing parties 9, 10 separate winding 2 of 2 in this case, more is not located on the same plane as the two left sides 11, 12 separate winding 2. Two right-wing parties are located in a plane higher than the two left sides. However, it is also possible, and Vice versa.

9 and 10, located in the coiled coil from the outside, it is more strongly inclined than side 1 and 12, located in the coiled coil inside, thus forming a quadrilateral with two adjacent short sides of equal length and two adjacent long sides of equal length. The individual segments 2 can be contiguous with the outer plane, and the inner plane, creating a closed shape, and the space can be filled optimally.

As in all embodiments, in this case also by the geometry of the circuit and the maximum filling of the outer planes can be waived. Explorer 4 figure 2 schematically presents the spiral line, regardless of the fact that several coils can be placed perpendicular to the plane of projection before starting a new layer. Similarly, you can make a separate winding of two or more conductors, which in the finished winding is connected in parallel.

Figure 3 shows a detailed view of an embodiment of a separate winding 2 in a distributed form in the unfolded flat condition. The conductor 4 is again shown schematically by line. Each of the conductors changes direction at the bottom and the upper end of the plane, passing forth perpendicular to the plane of projection. The conductors, which in the finished coil will be located on the outer plane, shown thickened. In the illustrated waples the Institute on the right are side 9, 10. However, the mirror placement is equivalent. Figure 3 can be seen most clearly that the sides 9, 10 located in the coiled coil outside, leaning more heavily than the sides 11, 12 located in the coiled coil inside. The individual segments 2 can be placed side by side with the outer plane, and the inner plane, forming a closed shape, and the space can be filled optimally. Like all other incarnations, in this case also by the geometry of the circuit and the maximum filling of the outer planes can be waived. The direction of winding, it is not predetermined in its final form; the beginning 5 or winding end of the winding 6 can be placed at the top.

Figure 4 provides a detailed representation of a single winding according to another embodiment in the unfolded flat condition. It has a distributed form, in which the plane of the changes not only at the ends of the axis, but every time I move from one side to the next. Figure 4 for the outer plane provided by the sides 9 and 11 and to the inner plane of the winding is provided by the sides 10 and 12. Thanks to an inclined position relative to the axis of symmetry 3 in this embodiment it is also possible to achieve a closed form and dense filling of the outer and inner layer. As in the other embodiments, in this case is also from the geometric circuit and the maximum filling of the outer planes can be waived.

Figure 5 shows the contours of the individual windings of the other two embodiments in the unfolded flat condition. In the drawing displayed initial end section 5 and the terminating end section 6, while the conductors are not shown. Segment 13, less inclined, is located between the sides 9 and 10, and similarly the segment 14 between the sides 11 and 12. Segments 13 and 14 can be performed slightly inclined, as shown in the drawing to the left, or straight, as shown in the drawing to the right. Slightly oblique design has a beneficial effect on the stability of the winding compared to fully direct the embodiment, since the winding is thus shifted or twisted in this part. The circuit shows a concentric embodiment, including a typical allowance 8. Similarly, the design is less inclined intermediate segments 13 and 14 can, however, also be applied to a distributed winding form, shown in Figure 3 without these intermediate segments.

Figure 6 is given a schematic representation of the location of layers overlapping six separate concentric windings 2. The drawing corresponds to the configuration of the linear motors. It can also be considered a cylindrical winding in the unfolded flat condition. On this drawing the hidden parts shown with a dashed line. The conductors and the ends of the windings on the drawing is not on asana.

Each of the separate windings 2 is here placed near one another, creating a closed form. Each group of windings must be placed on top of the neighboring groups of the winding on one side (right here), and at the same time it should be placed below the neighboring groups of the winding on the opposite side (here on the left).

In addition, these groups of windings must be Packed more densely. This requires a vertical offset in each partial winding, namely twice, top and bottom, making it possible that one half ran and half stayed with the offset in the opposite direction. In order to perform vertical offset needed some piece of wire, which would not affect the costs of the regularity of the winding.

Strip conductor windings in the part which is "active" for the engine, that is, in which electric current flows, remains regular and parallel with that of the adjacent winding group to pack close to each other. The allowance in the neutral zone is designed as a segment of the conductor required for the vertical offset. This allowance in neutral zone allows vertical displacement of the two halves of the partial windings without damage. The bending in the vertical offset corresponding to half of the partial windings, in this case, UCO is aceveda on repeat value. This value must be considered in the winding process so that the resulting partial winding support optimum geometry after the bend in the vertical offset.

7 shows a schematic representation of two separate concentric windings, layered one on top of another, overlapping, each with an initial end section 5 and the final end section 6 of the conductor. You can see that the final leaf area of individual windings in this configuration accepts such position that is immediately adjacent to the starting end part adjacent individual windings. In this position it is possible to electrically connect the two data of phase with each other, thereby forming the connecting conductors 7 of the winding 1.

On Figa and 8b schematically shows the axial projection of the contours of individual windings in concentric form 2A and a separate winding in a distribution form 2b in a cylindrical winding. The conductors 4 and the connecting wires 7 are not shown. Well you can see that one side 10 is located in the outer cylinder 15 and one side 11 is located in the inner cylinder 16, that is, between these parties is provided by the radial offset 17. Relevant other parties in this projection are not visible because they are located axially behind the front of the parties.

In the result, the present invention can be manufactured motors with windings, having a high packing density, allowing to reach a good degree of automation. Reduced waste, and reduced the imbalance. All of this contributes to the technical advantages, coupled with lower costs.

1. An electric motor having a coil with an air core (1), made up of many separate windings (2)made of a conductor (4)in which the individual winding (2) are superimposed on each other overlap, characterized in that the individual windings (2) pre-attached to this form, what is the offset (17) in at least two opposite corners, so that half of the parties is located in the inner hollow cylinder (16), and half of the parties is located in the outer hollow cylinder (15) without overlapping the inner hollow cylinder (16)with separate windings (2) forming, overlapping each other lap winding, curved around the axis of rotation of the engine and together form a hollow cylinder, including the outer hollow cylinder (15) and the inner hollow cylinder (16).

2. Electric motor according to claim 1, characterized in that a separate winding (2), being in the deployed form, arranged in a spiral around an axis which, when the coil (1) is in the collapsed state, is held in the radial direction so that the conductors (4) in the neutral zone are virtually the ski tangentially.

3. Electric motor according to claim 1, characterized in that the individual windings are provided with additional quantity of conductor material (4) as of the allowance (8) in the area of displacement (17), which forms a preferably U-shaped or loop-shaped bulge on the inner contour of the individual windings.

4. Electric linear motor having a coil with an air core (1), made up of many separate windings (2)made of a conductor (4)in which the individual winding (2) are superimposed on each other overlap, characterized in that the individual windings (2) pre-attached to this form, what is the offset (17) in at least two opposite corners, so that half of the parties is located in a first plane (16), and half of the parties is located in the second plane (15) without overlapping the first plane (16), with separate windings (2) forming, overlapping each other lap winding, together form a flat coil that includes a first plane (15) and the second plane (16), and a winding provided with an additional quantity of conductor material (4) as of the allowance (8) in the area of displacement (17), which forms a preferably U-shaped or loop-shaped bulge on the inner contour of the individual windings.

5. Electric motor according to claim 1 , or characterized in that the inner and outer portions of the individual winding (2) are pre-specified form.

6. Electric motor according to claim 1, characterized in that a separate winding (2) is wound, in expanded form, around the axis, which, in the collapsed coil (1) is in the tangential direction so that the conductors (4) in the neutral zone are almost radially, thus creating an offset (17).

7. Electric motor according to claim 1, characterized in that in addition to the radial displacement (17) on both ends of the winding (1) single coil (2) contains two additional offset (17) in other points of the inversion.

8. Electric motor according to claim 1, characterized in that a separate winding (2) is asymmetric and, at least, a separate winding (2) in the unfolded flat condition is rectangular in shape with sides (9, 10, 11, 12) of unequal length and/or shape of a quadrilateral with two adjacent short sides of equal length and two adjacent long sides of equal length.

9. Electric motor according to claim 1, characterized in that a separate winding (2) is provided with a separate coils having between, in the ideal case, the adjacent diagonal sections in the axial Central position, less inclined section located parallel to the axis, and the said section forms W is typolink.

10. Electric motor according to claim 1 or 4, characterized in that the isolated individual conductors (4) entourage in tow before winding.

11. Electric motor according to claim 1 or 4, characterized in that a separate winding (2) contains the initial leaf area (5) and a trailing end section (6) of the single-layer or multi-layer conductor (4), forming a separate winding (2), with initial and final end sections (5, 6), bred out in the region of one of the corners of the individual winding (2).

12. Electric motor according to claim 1 or 4, characterized in that one of the initial tail section (5) of the first separate winding (2) is connected to a terminating end section (6) of the second separate winding (2) with the formation of the connecting wires (7).

13. The electric motor 12, characterized in that the winding (1) is made of separate windings (2).

14. Method of manufacturing electric motor made according to any one of claims 1 to 13, characterized in that the initial tail section (5) of the layer of conductors of the first separate winding (2) is electrically connected to a terminating end section (6) of adjacent individual windings (2), with initial tail section (5) of the conductor (4) first separate winding (2) is passed along the outer side of the second single winding (2) to the terminating end portion (6) Provo is Nika (4) a second, separate winding (2).

15. The method according to 14, characterized in that each of the conductors (4) changes the plane on the lower and upper ends (18, 19), passing perpendicular to the plane of projection.

16. The method according to 14 or 15, characterized in that the parties(9, 10, 11, 12), outside in the coiled coil (2), tilt more heavily than the side(9, 10, 11, 12), located inside the rolled coil (2).