Method for manufacturing of electric machine rotor winding

FIELD: electricity.

SUBSTANCE: invention is related to the field of electric engineering and concerns technology for manufacturing of electric machine rotor winding. Method is suggested for manufacturing of electric machine (10) rotor winding, comprising at least four excitation poles (P) installed in stator (11), collector rotor (13), having grooves arranged along circumference and pole teeth (Z), number of which differs from number of excitation poles, sections (S) of winding and the same number of collector plates (L), number of which is at least twice more than number of pole teeth (Z). As sections (S) are wound onto pole teeth by winding wire in continuous mode, after fixation of winding wire (17) on initial plate (La) on the first pole - tooth (Z1) the first section (S1) of winding is wound with selected angle shift (φ₀) relative to initial plate (La), then winding wire (17) with specified pitch (Y) along collector is fixed on another collector plate (L), which is a final plate (Le) for wound section, then serially from each collector plate (L) winding section (S) is wound onto pole tooth (Z) with lowest deviation (Wf) of selected angle shift (φ₀) from electric angle identified by pole division of stator, afterwards winding wire (17) is entered in contact with another plate (Le), which is spaced by specified pitch (Y) along collector until all winding sections (S) are wound on pole teeth (Z).

EFFECT: provision of low pulsations of rotation torque and long service life due to optimal commutation of winding sections (S).

15 cl, 13 dwg

The technical field to which the invention relates.

The invention relates to a method of manufacturing a rotor winding of an electric machine.

The level of technology

From DE 19757279 C1 is known to use a four-pole motor commutator of the rotor (armature) 12 collector plates 12 attached sections of the winding to achieve low ripple torque and good commutation. In diametrically opposite plate is connected between a pin jumpers to make the power rotor symmetric and guarantee it with only one brush pair. In such machines the current in the rotor winding is distributed not according to two branches of the windings, and through jumpers on the four branches of the windings with the disadvantage that each branch has consistently enabled only half sections. Because of this increases the switching voltage in the coils. The result is increased wear of the carbon brushes on the manifold and, thus, the corresponding limit service or resource of the motor. In addition, sections of the rotor are wound onto three pole teeth each, resulting in their frontal part of the cross on the end sides of the rotor. This increases the departure of heads of sections and extend the connection between the heads, which is are material-intensive and lead to high thermal losses.

From patent US winding 4532449 known four-pole electric machine with a commutator rotor, in which the number of winding sections is only half the number of collector plates. There are five sections are supplied from one brush pair after 10 plates. This section is continuously wound in the form of sections of the winding, while the transition from one section to the next one pole tooth missing. The beginning and the end sections is introduced into contact with the plates, between which an arbitrary remains one plate. For power supply sections these free contact plates are connected to jumpers with opposing plates, in connection with the winding sections. This solution has the disadvantage that due to the increased voltage between the collector plates in the presence of five instead of twelve sections occurs reinforced sparking under the brushes, which reduces the durability of the collector, thereby reducing the service life of the machine.

Disclosure of inventions

The present invention was based on the task of improving commutation in electrical machines with a large number of poles, with sections of the winding on the pole teeth, which would increase the durability of the machine.

Proposed in the invention is a method of manufacturing a rotor winding of an electric machine, characterized by the profile the additional features of claim 1 claims, this has the advantage that wound on pole teeth and evenly distributed winding section occupy in relation to the pole division (step) stator position with the lowest possible deviation from the electrical angle. This allows you to minimize switching loss and radial forces acting on the rotor and, thereby, increase the service life of the machine. In addition, through the use of sections of the winding can be avoided outstanding and long connections windshields parts. Due to equal an even number of sections of the winding and the collector plate sections are evenly distributed in only two branches.

In dependent claims disclosed private and preferred embodiments of the method, characterized by the features of independent claim.

So, easy and cost-effective manufacturing of the winding of the rotor is due to the fact that several sections of the winding, and preferably all sections of the winding, wound each other one winding wire without interrupting him, and the beginning and end sections of the winding enter into contact with the respective collector plates by type of wave winding in the same direction of winding with a specified step by collector and the end plate of the previous section forms the starting plate for the next winding section. While Sha is Y winding of the winding sections on the collector is preferably set depending on the number of plates 1 and p-number of pole pairs of the stator from the condition: |Y-1/p|≤0,5. In addition, a simple way outlet end of the first section of the winding is introduced into contact with the plate, which was previously defined by the equation Le1=(La1+Y) modulo 1, and that for the next winding section winding is the initial plate. Then each following section of the winding is introduced into contact with the plates of the collector with the specified step Y by collector.

To find a position for each section of the winding, optimal in terms of polar division of the stator, in the particular embodiment of the invention each time before winding the next section of the winding, first determine the deviation of a given angular shift from defined pole by dividing the electrical angle for each of the pole teeth of the rotor, and then compare the absolute value of the angular deviation of each other, by this comparison, determine the pole teeth with the least deviation from the electrical angle and later on this pole wave wound the next section of the winding. With this aim in private embodiment of the invention it is proposed to determine for each pole tooth deviation from Wf electrical angle as the cosine of recurrent with respect to the number of pairs of poles of the angular deviation by the following equation:

Wf(j)=cos[2π×p/z×(j-Lai/M)],

where the multiplier M=s/z denotes the number of section the second winding on the pole teeth, s - the total number of winding sections, z is the number of pole teeth, a j is the corresponding pole tooth. Definition of least deviation given angular shift from the electrical angle in the case of the use of electronic computing machines is simplified if we define and compare the values of the deviations from the cosine of the electrical angle, and the next section of the winding is wound on the pole tooth with the greatest absolute value of the cosine of the deviation from the electrical angle. In addition, when the direction of winding of the winding sections may be determined by the sign of the value of the cosine of the deviation from the electrical angle. Because when there are many pole teeth for several pole teeth can be defined equal deviations from the electrical angle, to achieve short connections between the plates and sections of the winding serves to wind the winding section to the corresponding pole tooth, located in the area between the start and end plates of the sections of the winding. Next, to achieve a uniform distribution of the winding sections on all the pole teeth is proposed to wind each section of the winding to the next pole tooth, yet not carrying a given number of winding sections. Avoid long connections between the plates and sections of the winding on the side of the collector rotor 13 before Agueda magnet wire between the start or end plate and the winding section to pass between two spaced closer pole teeth to the rear side of the anchor, from there, in particular, between the other two pole teeth back to front and then to the winding section or plate.

To implement the above stages of the method provides the possibility to determine the initial plate and end plate, and pole teeth and the direction of winding of the winding sections using the computer on the table of the winding, which is injected into the winding machine and which is fulfilled by him during the winding of the winding sections.

In appropriate private embodiment of the invention as applied to a six-pole electric machine on its rotor by means of a winding machine for ten pole teeth continuously wound one after another twenty sections of the winding and step by collector in seven plates section of the winding is introduced into contact with twenty plates of the collector.

For four-pole electric machine, its the rotor by means of a winding machine for five pole teeth continuously wound one after another fifteen sections of the winding and step by collector in eight plates section of the winding is introduced into contact with fifteen plates of the collector.

For vosmipolosnoy electric cars on its rotor by means of a winding machine in nine pole teeth continuously wound one after another twenty-seven sections of the winding and at step collecto is at seven plates section of the winding is introduced into contact with twenty-seven plates of the collector.

For desaturases electric cars on its rotor by means of a winding machine on twelve pole teeth continuously wound one after another twenty-four sections of the winding and when you step on the collector five plates section of the winding is introduced into contact with twenty-four plates of the collector.

Brief description of drawings

Below the invention is described in more detail on the example of some preferred variants of its implementation with reference to the accompanying drawings on which is shown:

figure 1 - schematic representation proposed in the invention of the electric machine when viewed from the front,

figure 2 - scan machine, figure 1 shows, in schematic image with the first winding section,

figure 3 - table winding composed proposed in the invention method, in the first embodiment of the invention,

figure 4(a)-4(d) in the schematic sketch of manufacturing rotor winding on the winding table, figure 3 shows four stages (a)-(g),

figure 5 - table winding to a second example embodiment of the invention,

figure 6 - schematic representation of the machine with the manufacturing of the first four sections of the winding on the winding table, shown in figure 5,

7 is a table of the winding to the third variant embodiment of the invention,

on Fig - electric machine in schematic the second image with the first four sections of the winding, made for the winding table, shown in Fig.7,

figure 9 - table of the winding to the fourth variant embodiment of the invention,

figure 10 - electric machine in a schematic view, with the first four sections of the winding, is made by winding table shown in Fig.9.

The implementation of the invention

In figure 1 for the first variant embodiment of the invention schematically in a front view depicted and labeled pos.10 excited by a permanent magnet pole of the direct current motor, representing an example of the electric machine. Such machines are used preferably for servo drives, fans, etc. in cars and under high loads, and must operate reliably as possible, during the entire life of the vehicle. In accordance with this design should be durable. Electric machine 10 includes a six-pole stator 11, which through the working air gap 12 communicates with the collector rotor or armature 13, hereinafter referred to collectively simply by the rotor. The rotor 13 comprises a laminated stack of the package 14, mounted on a supported on both sides of the shaft 15. The circumference of the periphery of the laminated package 14 are ten equally spaced pole teeth Z, between which made grooves for placement in total, wadati sections S of the winding 18 of the rotor. This section's winding wound winding machine in pairs around each pole tooth Z. In this section S of the winding in a special way connected with the reservoir 16 is mounted on the front face side of the laminated package 14 on the shaft 15 of the rotor. The reservoir 16 contains twenty evenly distributed around the circumference of the plates L, interacting with the two stationary carbon brushes B1, B2. Carbon brushes are displaced with respect to each other by 180° when the electric machine is supplied by a constant current. However, ten pole teeth Z of the rotor 13 interact with three pairs p of poles excitation of the stator 11. In order to achieve the minimum ripple torque of the electric machine, the number of pole teeth different from the number of poles excitation.

Figure 2 schematically depicts the scan motor 10 DC, shown in figure 1, which is illustrated in more detail the method of winding for the manufacture and location of sections S of the winding on the pole teeth Z of the rotor 13. On the above figure shows a six-pole stator 11, ten pole teeth Z1-Z10, the first section S1 of the coil and twenty plates L1-L20 collector 16. The position of the first section of the winding is chosen arbitrarily and is necessary in this case, the first pole tooth Z1. Next, the first pole tooth Z1 with the first section S1 oblock is correlated with the middle of the North pole of the stator 11. This correspondence also randomly selected. In addition, a randomly selected according collector plates L and the pole teeth Z is chosen in this case so that the first pole tooth Z1 was exactly at the height of the gap between the plates L5, L6 collector 16. This position must have 2 on the circumference of the angular position φ=0°. This implies that adjacent the South pole of the stator 11 is in position 60°, the adjacent pole teeth Z2 is in position 36°, and the next gap between the plates is in position 18°. Then found that all of the section's winding its beginning enter in contact with the primary plate La, a its end with the end plate Le. In figure 2 the plate L2 to the first section S1 of the winding forms a randomly chosen initial plate La1. Therefore, based on the position selected in this case, the plate L2 between the initial plate La1 section S1 of the winding and provided for this section of the pole tooth Z1 occurs angular shift φ₀average of 63°. In figure 2 the optimal position of the section S1 of the winding is in the middle under the pole (North pole) of the stator 11. For this provision, the deviation from the electrical angle is zero: Wf=0°.

To section S of the winding could be continuously wound on the pole teeth Z on the type of wave windings, for all partitions S winding and set the step Y by collector, which guarantees the possibility of introducing a lead end of each section of the winding in contact with a free plate of L. figure 2 step Y by collector provided in seven plates, i.e. Y=7. To compile the table windings figure 3 proposed in the invention method first provides the following definitions:

p = number of pole pairs

z = number of teeth

1 = number of plates

s = number of winding sections

M = multiplier = 1/z=s/z

Y = step by collector

Wf = the deviation from the electrical angle (deviation from the optimum position of the partitions S)

Wz = the number of turns of the sections of the winding S

i = the corresponding section 1, 2, 3...s winding

j = the corresponding pole tooth 1, 2, 3...z

In addition, for designing the winding must meet the following conditions:

p>1

p<z<4P

z≠2pz≠3p

M>1

M≠integer multiples of p

M≠integer divisors p

1=s=M*z

|Y-1/p|≤0,5

All the sections administered in the initial contact with La and end Le plates. After random assignment first plate La1 for all i's partition start and end plate are determined by the equation:

and Lei=(Lai+Y)mod1.

The range of unit values for plate 1 is in this example, with twenty plates from S1 to S20.

Then for each of the next section's rotor winding 13 when the first pass is for each pole teeth z is determined by the angular deviation from the optimal from the point of view of the development of torque and minimize sparking under the brush position, namely starting with the first section S1 of the winding with the same angular deviation of 0°. Consequently, depicted in figure 2, the dashed line the second section S2 of the winding optimal position with angular displacement φ₀=63° relative to the initial plate L9 would be the position between the pole teeth Z4 and Z5, as indicated by the dotted line. Other optimum position displaced with respect to each other, respectively, at one pole pitch (360°/2P), i.e., 60°. However, the pole teeth available for the second section S2 of the winding, is arranged with a deviation from the optimal positions defined by the pole division, called the deviation from the electrical angle. Therefore, for each section of the winding must be found pole teeth with the least deviation from one of the best provisions. In this case, to simplify the calculation, determine the value of the cosine of periodically varying relative to the pairs of poles of the deviations of each of the following sections from the electrical angle for each pole tooth by the equation:

The following passage defined for the i-th section of the winding deviation from Wf electrical angle at j's teeth are compared to determine the pole teeth Z or pole is ubci Z with the maximum value of the cosine of the deviation from Wf electrical angle. This is done by the equation:

where Wfmax is the largest predefined comparative value for the i-th section of the winding.

Sign defined by equation (2) deviations from Wf electrical angle indicates, does optimal position of the section of the winding to the North or South pole of the stator. When it is determined that starting with the first section S1 of the winding, the positive value of the cosine of the section S of the winding wound in the same direction to the right. For each i-th section of the winding in particular for her pole teeth Z, it follows that a negative value of the cosine of the deviation Wf(j) from the electrical angle of the direction of winding sections is changed, i.e. the section should nakativaetsa against the direction of winding of the first section to the left of the selected tooth Z.

Motor 10 DC, shown figure 1, using equations (1), (2) and (3) is shown in figure 3 table windings, with the first section S1 of the winding is located in figure 2 on the pole tooth Z1. Because the calculation of deviations from the electrical angle is performed using a computer, equations (2) and (3) are used for the first section.

For the first variant implementation of the invention given:

the number of pairs of poles p=3

- the number of pole teeth z=10

Chi is lo plates 1=20

- the number of winding sections s=20

the multiplier M=2

- step on the manifold Y=7

- number of turns Wz=11

These values meet the above conditions. Using both equations (1) for each partition Si windings are determined by the initial Lai and end Lei plate.

The introduction of the winding sections in contact with the header:

Determination of deviations from the electrical angle

Now, in respect of each section of the winding S for all pole teeth Z according to equation (2) calculates a corresponding deviation from Wf electrical angle.

Deviation from the electrical angle section S1 of the winding

Wf(j)=cos[2π×p/z×(j-Lai/M)]

Prong 1: Wf(l)=cos[2π×3/10×(1-2/2)]=1,0

Prong 2: Wf(2)=cos[2π×3/10×(2-2/2)]=-0,309

Prong 3: Wf(3)=cos[2π×3/10×(3-2/2)]=-0,809

C the Betz 4: Wf(4)=cos[2π×3/10×(4-2/2)]=0,809

Prong 5: Wf(5)=cos[2π×3/10×(5-2/2)]=0,309

Prong 6: Wf(6)=cos[2π×3/10×(6-2/2)]=-1,0

Prong 7: Wf(7)=cos[2π×3/10×(7-2/2)]=0,309

Prong 8: Wf(8)=cos[2π×3/10×(8-2/2)]=0,809

The prong 9: Wf(9)=cos[2π×3/10×(9-2/2)]=-0,809

Prong 10: Wf(10)=cos[2π×3/10×(10-2/2)]=-0,309

The following passage using equation (3) for section S1 of the winding is determined by the pole teeth with the least deviation from Wf electrical angle or the maximum value of the cosine Wfmax deviations from the electrical angle.

Wfmax=max(|Wf(1)|, |Wf(2)|, |Wf(3)|...,)=1,0

Comparison of deviations from the electrical angle

|Wf(1)|=Wfmax:1,0=1,0: true

|Wf(2)|=Wfmax:0,309≠1,0: condition not met

|Wf(3)|=Wfmax:0,809≠1,0: condition not met

|Wf(4)|=Wfmax:0,309≠1,0: condition not met

|Wf(5)|=Wfmax:0,809≠1,0: condition not met

|Wf(6)|=Wfmax:1,0=1,0: true

|Wf(7)|=Wfmax:0,309≠1,0: condition not met

|Wf(8)|=Wfmax:0,809≠1,0: condition not met

|Wf(9)|=Wfmax:0,809≠1,0: condition not met

|Wf(10)|=Wfmax:0,309≠1,0: condition not met

Because there are several teeth-poles Z1 and Z6 have the same smallest absolute deviation from the electrical angle of these pole teeth is chosen the pole teeth Z, which is in the area between the initial La and end Le plates section S of the winding. In addition, they check if you have selected already for the selected pole teeth Z given number M of sections S of the winding.

The result of the comparison

The first section S1 of the exchange rate the TCI can be wound on the tooth Z. The calculated value is positive, so the section S1 of the winding is wound to the right. Thus, the first row of the table windings figure 3.

The same calculations are carried out according to equation (2) for the second section S2 of the winding with the initial plate La2=9.

Deviations of the second section S2 of the winding from the electrical angle:

Wf(j)=cos[2π×p/z×(j-Lai/M)]

Prong 1: Wf(l)=cos[2π×3/10×(1-9/2)]=0,951

Prong 2: Wf(2)=cos[2π×3/10×(2-9/2)]=0,000

Prong 3: Wf(3)=cos[2π×3/10×(3-9/2)]=-0,951

Prong 4: Wf(4)=cos[2π×3/10×(4-9/2)]=0,588

Prong 5: Wf(5)=cos[2π×3/10×(5-9/2)]=0,588

Prong 6: Wf(6)=cos[2π×3/10×(6-9/2)]=-0,951

Prong 7: Wf(7)=cos[2π×3/10×(7-9/2)]=0,000

Prong 8: Wf(8)=cos[2π×3/10×(8-9/2)]=0,951

The prong 9: Wf(9)=cos[2π×3/10×(9-9/2)]=-0,588

Prong 10: Wf(10)=cos[2π×3/10×(10-9/2)]=-0,588

The following passage using equation (3) for section S2 of the winding is determined by the pole teeth with the least deviation from Wf electrical angle or the maximum value of the cosine Wfmax deviations from the electrical angle.

Wfmax=max(|Wf(1)|, |Wf(2)|, |Wf(3)|, ...)=0,951

Comparison of deviations from the electrical angle

|Wf(1)|=Wfmax:0,951=0,951: true

|Wf(2)|=Wfmax:0,000≠0,951: condition not met

|Wf(3)|=Wfmax:0,951=0,951: true

|Wf(4)|=Wfmax:0,588≠0,951: condition not met

|Wf(5)|=Wfmax:0,588≠0,951: condition not met

|Wf(6)|=Wfmax:0,951=0,951: true

|Wf(7)|=Wfmax:0,000≠0,951: condition not met

|Wf(8)|=Wfmax:0,951=0,951: true

|Wf(9)|=Wfmax:0,588≠0,951: condition is not observed is prohibited

|Wf(10)|=Wfmax:0,588≠0,951: condition not met

Because there are several teeth-poles have the same smallest absolute deviation from these pole teeth is chosen the pole teeth Z, which is in the area between the initial La and end Le plates section S of the winding. In addition, they check if you have selected already for the selected pole teeth Z given number M of sections S of the winding.

The result of the comparison

The second section S2 of the winding can be wound on the teeth 3. The calculated value is negative, so the section S2 winding is wound to the left. Thus, is defined as the second line of the table windings figure 3.

Similarly, using equations (2) and (3) are carried out the same calculations for the other sections of the winding, the third through the twentieth, and thus the line is drawn up the winding table, shown in figure 3. To wrap the rotor 13 of the motor 10 DC proposed in the invention method, a filament winding machine first introduced the winding table, shown in figure 3.

Winding machine (not shown) by line fulfills the winding table, shown in figure 3, and section S1-S20 coil continuously wound each other and enter into contact with the respective plates L of the manifold 16. Figure 4(a)-4(g) are depicted and described below, the manufacturing sections of the winding table, showing the Noah figure 3 the four stages (a)-(g).

First, at the stage shown in figure 4(a), magnet wire 17 is injected him 17A in contact with the plate L2. From there it is conducted to the pole tooth Z1, and section S1 winding wound on his right arrow. The end of this section of the winding is put into contact with the plate L9. From there to the pole tooth Z3 left is wound around the second section S2 of the winding, the end of which is placed on the plate L16. From there to the pole tooth Z8 right wound section S3 of the winding, the end of which is placed on the plate L3. From there to the pole tooth Z10 wound left section S4 of the winding, the end of which is put into contact with the plate L10. From there to the pole tooth Z5 wound right section S5 of the winding, the end of which is put into contact with the plate L17. With plate L17 magnet wire is transferred on the arrow at the stage shown in figure 4(6).

Here with plate L17 on the pole tooth Z7 left winded section S6 of the winding, the end of which is put into contact with the plate L4. From there to the pole tooth Z2 wound right section S7 of the winding, the end of which is put into contact with the plate L11. With plate L11 on the pole tooth Z4 left winded section S8 of the winding, the end of which is put into contact with the plate L18. From there to the pole tooth Z9 right wound section S9 of the winding, the end of which is put into contact with the plate L5. With the plate L5 on the pole tooth Z1 left on atives section S10 winding, end of which is put into contact with the plate L12. With plate L12 magnet wire is transferred on the arrow at the stage shown in figure 4(b).

Proceeding from the plate L12, pole tooth Z6 right wound section S11 of the winding, the end of which is put into contact with the plate L19. From there to the pole tooth Z8 left winded section S12 of the winding, the end of which is put into contact with the plate L6. From there to the pole tooth Z3 right wound section S13 of the winding, the end of which is put into contact with the plate L13. With plate L13 on the pole tooth Z5 left winded section S14 winding, the end of which is put into contact with the plate L20. From there to the pole tooth Z10 right wound section S15 of the winding, the end of which is put into contact with the plate L7. From there, magnet wire is transferred on the arrow at the stage shown in figure 4(d).

With plates L7 on pole teeth Z2 wound left section S16 winding, the end of which is put into contact with the plate L14. From there to the pole tooth Z7 right wound section S17 winding, the end of which is put into contact with the plate L1. From there to the pole tooth Z9 left winded section S18 winding, the end of which is put into contact with the plate L8. With the plate L8 on the pole tooth Z4 right wound section S19 winding, the end of which is placed on the plate L15. Finally on the pole tooth Z6 left negativesense S20 winding, end of which is placed on the plate L2. Here is the end 17b of the winding wire 17 is cut off. Thus all twenty of the winding sections being successively wound evenly distributed on all the pole teeth z Of the winding table in figure 3, and figure 1, it follows that for each of the ten pole teeth Z wound in two sections S of the winding.

In the second embodiment of the invention described above should be compiled depicted in figure 5, the winding table for four pole direct current motor with a different number of teeth z, the number s of the winding sections and the number 1 plate collector.

For the second variant implementation of the invention given:

- the number of pole pairs p=2

- the number of pole teeth z=5

- the number of plates 1=15

- the number of winding sections s=15

the multiplier M=3

- step on the manifold Y=8

- number of turns Wz=11

These values meet the above conditions. Using both equations (1) for each partition Si windings are determined by the initial Lai and end Lei plate.

The introduction of the winding sections in contact with the header:

Determination of deviations from the electrical angle

In respect of each section S oblock is for all the pole teeth Z according to equation (2) calculates a corresponding deviation from Wf electrical angle.

Deviation from the electrical angle to the first section S1 of the winding

Wf(j)=cos[2π×p/z×(j-Lai/M)]

Prong 1: Wf(1)=cos[2π×2/5×(1-3/3)]=1,000

Prong 2: Wf(2)=cos[2π×2/5×(2-3/3)]=-0,809

Prong 3: Wf(3)=cos[2π×2/5×(3-3/3)]=0,309

Prong 4: Wf(4)=cos[2π×2/5×(4-3/3)]=0,309

Prong 5: Wf(5)=cos[2π×2/5×(5-3/3)]=-0,809

The following passage using equation (3) for section S1 of the winding is determined by the pole teeth with the least deviation from Wf electrical angle or the maximum value of the cosine Wfmax deviations from the electrical angle.

Wfmax=max(|Wf(1)|, |Wf(2)|, |Wf(3)|, ...)=1,000

Comparison of deviations from the electrical angle

|Wf(1)|=Wfmax:1=1: the condition is met

|Wf(2)|=Wfmax:0,809≠1: the condition is not met

|Wf(3)|=Wfmax:0,309≠1: the condition is not met

|Wf(4)|=Wfmax:0,309≠1: the condition is not met

|Wf(5)|=Wfmax:0,809≠1: the condition is not met

The result of the comparison

Section S1 of the winding can be wound on the teeth Z1. The calculated value is positive, so the section S1 of the winding is wound to the right. Thus, the first row of the table winding figure 5.

The deviation of the second section S2 of the winding from the electrical angle

Wf(j)=cos[2π×p/z×(j-Lai/M)]

Prong 1: Wf(1)=cos[2π×2/5×(1-11/3)]=0,914

Prong 2: Wf(2)=cos[2π×2/5×(2-11/3)]=-0,500

Prong 3: Wf(3)=cos[2π×2/5×(3-11/3)]=-0,105

Prong 4: Wf(4)=cos[2π×2/5×(4-11/3)]=0,669

Prong 5: Wf(5)=cos[2π×2/5×(5-11/3)]=-0,978

The following passage using equation (3) for section S2 of the winding is determined by the pole teeth on the smaller deviation from Wf electrical angle or the maximum value of the cosine Wfmax deviations from the electrical angle,

Wfmax=max(|Wf(L)|, |Wf(2)|, |Wf(3)|, ...)=0,978

Comparison of deviations from the electrical angle

|Wf(1)|=Wfmax:0,9141≠0,978: condition not met

|Wf(2)|=Wfmax:0,500≠0,978: condition not met

|Wf(3)|=Wfmax:0,105≠0,978: condition not met

|Wf(4)|=Wfmax:0,669≠0,978: condition not met

|Wf(5)|=Wfmax:0,978=0,978: true

The result of the comparison

Section S2 of the winding can be wound on the tooth Z5. The calculated value is negative, so the section S2 winding is wound to the left. Thus, the determined second table row winding figure 5.

The same calculations are carried out using equations (2) and (3) in the same manner for the remaining sections of the winding from the third to the fifteenth, and thus the line is drawn table winding figure 5.

Figure 6 depicts and describes the production of sections S1-S4 of the winding at the first stage.

When this magnet wire 17 is first introduced its beginning 17A in contact with the plate L3. From there he goes to the pole tooth Z1, to which the right is wound section S1 of the winding. The end of this section of the winding is put into contact with the plate L11. From there to the pole tooth Z5 left winded section S2 of the winding, the end of which is placed on the plate L4. From there to the pole tooth Z5 also left winded section S3 of the winding, the end of which is placed on the plate L12. From there to the pole tooth Z4 right wound section S4 of the winding, the rates of which shall be put into contact with the plate L5. With the plate L5 magnet wire 17 is transferred on the arrow to the beginning of the section S6 of the winding, and the winding table is being coiling machine as in the first embodiment of the invention, while the rotor of the machine will not wound all the sections of the winding.

In the third embodiment of the invention described above should be compiled depicted in Fig.7. table winding for volmerange direct-current motor with a different number of teeth z, the number s of the winding sections and the number 1 plate.

For the third variant embodiment of the invention given:

the number of pairs of poles p=4

- the number of pole teeth z=9

- the number of plates 1=27

- the number of winding sections s=27

the multiplier M=3

- step on the manifold Y=7

- number of turns Wz=15

These values meet the above conditions. Using both equations (1) for each partition Si are determined by the initial Lai and end Lei plate.

The introduction of the winding sections in contact with the header:

Determining deviations from elektricheska the corner

In respect of each section of the winding S for all pole teeth Z according to equation (2) calculates a corresponding deviation from Wf electrical angle.

Deviation from the electrical angle section S1 of the winding

Wf(j)=cos[2π×p/z×G-Lai/M)]

Prong 1: Wf(1)=cos[2π×4/9×(1-3/3)]=-1,000

Prong 2: Wf(2)=cos[2π×4/9×(2-3/3)]=-0,940

Prong 3: Wf(3)=cos[2π×4/9×(3-3/3)]=0,766

Prong 4: Wf(4)=cos[2π×4/9×(4-3/3)]=-0,500

Prong 5: Wf(5)=cos[2π×4/9×(5-3/3)]=0,174

Prong 6: Wf(6)=cos[2π×4/9×(6-3/3)]=0,174

Prong 7: Wf(7)=cos[2π×4/9×(7-3/3)]=-0,500

Prong 8:: Wf(8)=cos[2π×4/9×(8-3/3)]=0,766

The prong 9 Wf(9)=cos[2π×4/9×(9-3/3)]=-0,940

The following passage using equation (3) for section S1 of the winding is determined by the pole teeth with the least deviation from Wf electrical angle or the maximum value of the cosine Wfmax deviations from the electrical angle.

Wfmax=max(|Wf(1)|, |Wf(2)j, |Wf(3)|, ...)=1,000

Comparison of deviations from the electrical angle

|Wf(1)|=Wfmax:1=1: the condition is met

|Wf(2)|=Wfmax:0,94≠1: the condition is not met

|Wf(3)|=Wfmax:0,766≠1: the condition is not met

|Wf(4)|=Wfmax:0,5≠1: the condition is not met

|Wf(5)|=Wfmax:0,174≠1: the condition is not met

|Wf(6)|=Wfmax:0,174≠1: the condition is not met

|Wf(7)|=Wfmax:0,5≠1: the condition is not met

|Wf(8)|=Wfmax:0,766≠1: the condition is not met

|Wf(9)|=Wfmax:0,94≠1: the condition is not met

The result of the comparison

Section S1 of the winding can be wound on the teeth Z1. The calculated value is positive, so the section S1 of the winding is wound EAP is AVO. Thus, the first row of the table winding 7.

Deviation from the electrical angle section S2 winding

Wf(j)=cos[2π×p/z×(j-Lai/M)]

Prong 1: Wf(1)=cos[2π×4/9×(1-10/3)]=0,973

Prong 2: Wf(2)=cos[2π×4/9×(2-10/3)]=-0,835

Prong 3: Wf(3)=cos[2π×4/9×(3-10/3)]=0,597

Prong 4: Wf(4)=cos[2π×4/9×(4-10/3)]=-0,287

Prong 5: Wf(5)=cos[2π×4/9×(5-10/3)]=-0,058

Prong 6: Wf(6)=cos[2π×4/9×(6-10/3)]=0,396

Prong 7: Wf(7)=cos[2π×4/9×(7-10/3)]=-0,686

Prong 8: Wf(8)=cos[2π×4/9×(8-10/3)]=0,894

The prong 9: Wf(9)=cos[2π×4/9×(9-10/3)]=-0,993

The following passage using equation (3) for section S2 of the winding is determined by the pole teeth with the least deviation from Wf electrical angle or the maximum value of the cosine Wfmax deviations from the electrical angle.

Wfmax=max(|Wf(1)|, |Wf(2)|, |Wf(3)|, ...)=0,993

Comparison of deviations from the electrical angle

|Wf(1)|=Wfmax:0,973≠0,993: condition not met

|Wf(2)|=Wfmax:0,835≠0,993: condition not met

|Wf(3)|=Wfmax:0,597≠0,993: condition not met

|Wf(4)|=Wfmax:0,287≠0,993: condition not met

|Wf(5)|=Wfmax:0,058≠0,993: condition not met

|Wf(6)|=Wfmax:0,396≠0,993: condition not met

|Wf(7)|=Wfmax:China 0,686≠0,993: condition not met

|Wf(8)|=Wfmax:0,894≠0,993: condition not met

|Wf(9)|=Wfmax:0,993=0,993: true

The result of the comparison

Section S2 of the winding can be wound on the tooth Z9. The calculated value is negative, so the section S2 winding is wound to the left. Thus, the first row of the table is s winding 7.

The same calculations are carried out using equations (2) and (3) in the same manner for the remaining sections of the winding from the third to the twenty-seventh, and thus the line is drawn up the winding table 7.

On Fig shown and described the production of sections of the winding at the first stage with respect to the winding sections with the first (S1) on the fourth (S4).

In this first winding wire 17 is inserted his early 17A in contact with the plate L3. From there he goes to the pole tooth Z1, to which the right is wound section S1 of the winding. The end of this section of the winding is put into contact with the plate L10. From there to the pole tooth Z9 left winded section S2 of the winding, the end of which is placed on the plate L17. From there to the pole tooth Z9 also left winded section S3 of the winding, the end of which is placed on the plate L24. From there to the pole tooth Z8 right wound section S4 of the winding, the end of which is put into contact with the plate L4. With plates L4 magnet wire is transferred on the arrow to the beginning of the fifth section S5 of the winding, and the winding table is being coiling machine as in the first embodiment of the invention, while the rotor of the machine will not wound all the sections of the winding.

Avoid long connections on the side of the collector rotor 13 between the plates and sections of the winding may be advisable to skip the th magnet wire 17 between the initial plate La or end plate Le and section S of the winding between the spaced closer pole teeth Z to the rear side of the rotor, from there, in particular, between the other two pole teeth Z back to front and then to the section S of the winding or plate L, as shown in Fig dashed line around the section of the winding S3.

In the fourth embodiment of the invention described above should be compiled depicted in Fig.9 table winding for desyatiblochnoe direct-current motor with a different number of teeth z, the number s of the winding sections and the number 1 plate.

For the fourth variant embodiment of the invention given:

the number of pairs of poles p=5

- the number of pole teeth z=12

- the number of plates 1=24

- the number of winding sections s=24

the multiplier M=2

- step on the manifold Y=5

- number of turns Wz=18

These values meet the above conditions. Using both equations (1) for each partition Si windings are determined by the initial Lai and end Lei plate.

The introduction of the winding sections in contact with the header:

Determination of deviations from the electrical angle

In respect of each section of the winding S for all pole teeth Z according to equation (2) calculates a corresponding deviation from Wf electrical angle.

Deviation from the electrical angle section S1 of the winding

Wf(j)=cos[2π×p/z×(j-Lai/M)]

Prong 1: Wf(1)=cos[2π×5/12×(1-2/2)]=1,000

Prong 2: Wf(2)=cos[2π×5/12×(2-2/2)]=-0,866

Prong 3: Wf(3)=cos[2π×5/12×(3-2/2)]=0,500

Prong 4: Wf(4)=cos[2π×5/12×(4-2/2)]=0,000

Prong 5: Wf(5)=cos[2π×5/12×(5-2/2)]=-0,500

Prong 6: Wf(6)=cos[2π×5/12×(6-2/2)]=0,866

Prong 7: Wf(7)=cos[2π×5/12×(7-2/2)]=-1,000

Prong 8: Wf(8)=cos[2π×5/12×(8-2/2)]=0,866

The prong 9: Wf(9)=cos[2π×5/12×(9-2/2)]=-0,500

Prong 10: Wf(10)=cos[2π×5/12×(10-2/2)]=0,000

The prong 11: Wf(11)=cos[2π×5/12×(11-2/2)]=0,500

Prong 12: Wf(12)=cos[2π×5/12×(12-2/2)]=-0,866

The following passage using equation (3) for section S1 of the coil determine eleesa pole teeth with the least deviation from Wf electrical angle or the maximum value of the cosine Wfmax deviations from the electrical angle.

Wfmax=max(|Wf(1)|, |Wf(2)|, |Wf(3)|, ...)=1,000

Comparison of deviations from the electrical angle:

|Wf(1)|=Wfmax:1=1: the condition is met

|Wf(2)|=Wfmax:0,866≠1: the condition is not met

|Wf(3)|=Wfmax:0,5≠1: the condition is not met

|Wf(4)|=Wfmax:0,000≠1: the condition is not met

|Wf(5)|=Wfmax:0,5≠1: the condition is not met

|Wf(6)|=Wfmax:0,866≠1: the condition is not met

|Wf(7)|=Wfmax:1=1: the condition is met

|Wf(8)|=Wfmax:0,866≠1: the condition is not met

|Wf(9)|=Wfmax:0,5≠1: the condition is not met

Wf(10)|=Wfmax:0,000≠1: the condition is not met

|Wf(11)|=Wfmax:0,5≠1: the condition is not met

|Wf(12)|=Wfmax:0,866≠1: the condition is not met

The result of the comparison

Section S1 of the winding can be wound on the teeth Z1. The calculated value is positive, so the section S1 of the winding is wound to the right. Thus, the first row of the table windings on Fig.9.

Deviation from the electrical angle section S2 winding

Wf(j)=cos[2π×p/z×(j-Lai/M)]

Prong 1: Wf(1)=cos[1π×5/12×(1-7/2)]=0,966

Prong 2: Wf(2)=cos[2π×5/12×(2-7/2)]=-0,707

Prong 3: Wf(3)=cos[2π×5/12×(3-7/2)]=0,259

Prong 4: Wf(4)=cos[2π×5/12×(4-7/2)]=0,259

Prong 5: Wf(5)=cos[2π×5/12×(5-7/2)]=-0,707

Prong 6: Wf(6)=cos[2π×5/12×(6-7/2)]=0,966

Prong 7: Wf(7)=cos[2π×5/12×(7-7/2)]=-0,966

Prong 8: Wf(8)=cos[2π×5/12×(8-7/2)]=0,707

The prong 9: Wf(9)=cos[2π×5/12×(9-7/2)]=-0,259

Prong 10: Wf(10)=cos[2π×5/12×(10-7/2)]=-0,259

The prong 11: Wf(11)=cos[2π×5/12×(11-7/2)]=0,707

Prong 12: Wf(12)=cos[2π×5/12×(12-7/2)]=-0,966

The following passage using equation (3) for section S2 of the winding is determined by oluseyi prong with the least deviation from Wf electrical angle or the maximum value of the cosine Wfmax deviations from the electrical angle.

Wfmax=max(|Wf(1)|, |Wf(2)|, |Wf(3)|, ...)=0,966

Comparison of deviations from the electrical angle

|Wf(1)|=Wfmax:0,966=0,966: true

|Wf(2)|=Wfmax:0,707≠0,966: condition not met

|Wf(3)|=Wfmax:0,259≠0,966: condition not met

|Wf(4)|=Wfmax:0,259≠0,966: condition not met

|Wf(5)|=Wfmax:0,707≠0,966: condition not met

|Wf(6)|=Wfmax:0,966=0,966: true

|Wf(7)|=Wfmax:0,966=0,966: true

|Wf(8)|=Wfmax:0,707≠0,966: condition not met

|Wf(9)|=Wfmax:0,259≠0,966: condition not met

|Wf(10)|=Wfmax:0,259≠0,966: condition not met

|Wf(11)|=Wfmax:0,707≠0,966: condition not met

|Wf(12)|=Wfmax:0,966=0,966: true

The result of the comparison

Section S2 of the winding can be wound on the tooth Z6. The calculated value is positive, so the section S2 winding is wound to the right. Thus, the determined second row of the table windings on Fig.9.

The same calculations are carried out using equations (2) and (3) in the same manner for the remaining sections of the winding from the third through the twenty-fourth, and thus the line is drawn table windings on Fig.9.

Figure 10 depicts and describes the production of sections S1-S4 of the winding at the first stage.

In this first winding wire 17 is inserted his early 17A in contact with the plate L2. From there he goes to the pole tooth Z1, to which the right is wound section S1 of the winding. The end of this section of the winding is put into contact with the plates is th L7. From there to the pole tooth Z6 right wound section S2 of the winding, the end of which is placed on the plate L12. From there to the pole tooth Z6 also right wound section S3 of the winding, the end of which is placed on the plate L17. From there to the pole tooth Z11 right wound section S4 of the winding, the end of which is put into contact with the plate L22. With plate L22 magnet wire is transferred on the arrow to the beginning of the sixth section S6 of the winding, and the winding table is being coiling machine as in the first embodiment of the invention, while the rotor of the machine will not wound all the sections of the winding.

The possibility of carrying out the invention are not limited presented on the drawings variants, since under the following conditions:

p>1<z for the number of pairs of poles

z≠2P≠3p for the number of teeth

M=s/z for the above factor, and

|Y-1/p|≤0.5 for step by collector

there are many possible combinations of parameters embodiment of the invention.

In addition, to determine the deviation of the position of the winding sections from the electrical angle at the respective pole teeth instead of the value of the cosine in equation (2) can also use the sine ratio. Similarly, the designated pole by dividing the deviation from the electrical angle can be defined as arc (radiana) measure, if in equation (2 to omit the cosine. The absolute deviation of the winding sections computed over the entire circumference, can be obtained by eliminating from equation (2) parameter ”p”, which is also possible in the framework of the invention. However, the deviation from the electrical angle must be adjusted according to the number of poles, i.e. modulo 2π/2P. Also the deviation from the electrical angle can be determined in degrees, if you replace a member of the ”2π” with ”360°”, and the result is correct modulo 360°/2P. But in any case, to compile the table of the winding for each section should identify the pole teeth with the least deviation from the electrical angle.

In reeling machines-shifted by 180° with respect to each other measured including carriers or needles in the case of an even number s of the winding sections in figure 3 and 9 can also continuously nakativaetsa respectively half of them, i.e. the upper and lower half of the tables are winding are processed simultaneously by the respective planet carrier or needle.

1. A method of manufacturing a rotor winding of an electric machine, preferably an electric motor (10) DC containing at least four located in the stator (11) pole (P) excitation, the collector rotor (13)having spaced around the circumference of the grooves and the pole teeth (Z), the number of which is different from the number of poles of the excitation section (S) of the winding and the same collector the x plates (L), the number of which is at least twice the number of pole teeth, and the section of the winding is wound on the pole teeth of the winding wire (17) on reeling machine, preferably with a uniform distribution of the winding sections, including by winding in a continuous mode, wherein after fixing magnet wire (17) to the initial plate (La) on the first pole tooth (Z1) is wound first section (S1) of the winding with the specified number of turns on randomly selected angular shift (φ₀concerning its initial plate (La), then wrapping the wire (17) with a fixed step (Y) on a manifold fixed to the other of the collector plate (L), which for wound section end plate (Le), and then in series with each collector plate (L) wound section (S) of the winding on the pole tooth (Z), for which the deviation (Wf) selected angular shift (φ₀) from the electrical angle defined by the pole division, the smallest, and enter the magnet wire (17) in contact with the other plate (L), spaced at a given pitch (Y) by collector, until then, until the pole teeth (Z) will not wound all the sections (S) of the winding.

2. The method according to claim 1, characterized in that the step (Y) of the winding sections (S) of the winding by collector set depending on the number (1) plates and the number (p) of p is p poles of the stator (11) of the conditions: |Y-1/R|≤0.5 in.

3. The method according to claim 1 or 2, characterized in that the end of the first section (S) of the winding is introduced into contact with the plate (Le1), which is pre-defined by the equation Le1=(La1+Y)mod1 and which for the next winding section (S2) is the starting winding plate (La2), and then each following section (S) of the winding is introduced into contact with the plates (L) reservoir (16) with the specified pitch (Y) in the header.

4. The method according to claim 1 or 2, characterized in that each winding of the next section (S) winding first determine the deviation (Wf) from the electrical angle for each of the pole teeth (Z) of the rotor (13), then compare the absolute value of the angular deviation of each other, by this comparison, determine the pole teeth (Z) with the smallest deviation (Wf) from the electrical angle and this pole tooth is wound in the following section (S) of the winding.

5. The method according to claim 4, characterized in that each pole tooth (Z) deviation (Wf) from the electrical angle is preferably defined as the cosine of periodically varying in relation to the number (p) of pairs of poles of the angular deviation equation Wf(j)=cos[2π×p/z×(j-Lai/M)], where the multiplier M denotes the number of partitions (S) winding on pole teeth (Z)and j is the corresponding pole tooth (Z).

6. The method according to claim 5, characterized in that it defined for each partition (S) winding the values of the cosine is tkaniny (Wf) from the electrical angle compared between them and the appropriate section (S) of the winding wound on the pole tooth (Z) with the smallest deviation (Wf) from the electrical angle, preferably with the largest absolute value (Wfmax) cosine deviation from the electrical angle when the direction of winding sections (S) of the winding is determined by the sign of the value of the cosine of the deviation from the electrical angle.

7. The method according to claim 4, characterized in that in case of equal highest values (Wfmax) cosine deviation from the electrical angle for multiple pole teeth (Z) the following section (S) of the winding wound on the pole tooth (Z), is not yet carrying a given number (M) of the sections (S) of the winding.

8. The method according to claim 7, characterized in that the section (S) of the winding wound on the pole tooth (Z)in the zone between the primary plate (La) and end plate (Le) of this section (S) of the winding.

9. The method according to claim 1, characterized in that several sections (S) of the winding, and preferably all sections of the winding, wound each other one winding wire (17), without interrupting him, and the beginning and end sections of the winding enter into contact with the respective collector plates (L) the type of wave winding in the same direction of winding with a specified pitch (Y) in the header.

10. The method according to claim 1, characterized in that the magnet wire (17) between the initial plate (La) or end plate (Le) and section (S) of the winding pass between two spaced closer pole teeth (Z) to the rear side of the armature, thence, in private the tee, between the other two pole teeth (Z) back to front and then to the section (S) or winding plate (L).

11. The method according to claim 1, characterized in that the initial plate (La) and end plate (Le), and pole teeth (Z) and the direction of winding sections (S) of the winding is determined using a computer on the table of the winding, which is injected into the winding machine and which is fulfilled by him during the winding of the winding sections.

12. The method according to claim 1, characterized in that in the case of a four-pole electric machine on its rotor (13) using a winding machine for five pole teeth (Z) is continuously wound one after another fifteen sections (S) of the winding, and when the step (Y) by collector in eight plates section of the winding is introduced into contact with fifteen plates (L) of the collector (16).

13. The method according to claim 1, characterized in that in the case of a six-pole electric machine on its rotor (13) using a winding machine for ten pole teeth (Z) is continuously wound one after another twenty sections (S) of the winding, and when the step (Y) by collector in seven plates section of the winding is introduced into contact with twenty plates (L) of the collector (16).

14. The method according to claim 1, characterized in that in the case of vosmipolosnoy electric cars on its rotor (13) using a winding machine for nine pole teeth (Z) is continuously wound one after another twenty with the trade sections (S) of the winding, and when step (Y) by collector in seven plates section of the winding is introduced into contact with twenty-seven plates (L) of the collector (16).

15. The method according to claim 1, characterized in that in the case of desaturases electric cars on its rotor (13) using a winding machine on twelve pole teeth (Z) is continuously wound one after another twenty-four sections of the winding (S) of the winding, and when the step (Y) by collector in five plates section of the winding is introduced into contact with twenty-four plates (L) of the collector (16).