TWI442674B - Slotless motor coil module and the manufacturing method thereof - Google Patents

Description

Grooveless motor coil module and manufacturing method thereof

The invention relates to a method for manufacturing a slotless motor coil winding, and in particular to a method for manufacturing a coil module for curing.

Permanent magnet DC brushless motors are widely used in the high-tech industry, such as CD players, centrifuges or high-speed electric screwdrivers, because of their high speed, low noise and simple control.

The conventional internal transformation permanent magnet type brushless DC motor is shown in FIG. 1. The motor 10 includes a rotor core 11, a plurality of magnets 13, and a stator core 15. A plurality of magnets 13 are fixedly disposed around the rotor core 11, and the stator core 15 is disposed outside the rotor core 11 and spaced apart from the rotor core 11 by a gap. The inner side of the stator core 15 has a plurality of grooves 17 for winding the coil windings (not shown). The stator core 15 of such a structure is complicated by stamping or wire cutting, and the coil windings are difficult to access.

In order to improve the conventional motor, a slotless motor has been developed in which the stator core does not have a groove, and it is not necessary to wind the coil in the groove, but to fix the coil winding inside the stator core.

Since the coil winding of the slotless motor must be accurately fixed inside the stator, the three-phase windings may interfere with each other, which may cause an imbalance of the three-phase induced electromotive force. Moreover, the conventional coil windings are isolated from each other only by the insulating paper. In the case of no cogging, the coil winding has no way to dissipate heat through the slots of the stator core, so that it may be overheated and burned for a long time.

The method for manufacturing the slotless motor coil module of the present invention utilizes an insulating heat dissipation layer to cover a plurality of phase windings, and the manufactured coil module can be fixedly disposed on the inner side surface of the stator of the slotless motor to help the slotless The heat dissipation effect of the motor when it is running.

Embodiments of the present invention provide a method for manufacturing a slotless motor coil module, comprising preparing a coil winding, preparing a die casting fixture, and then placing the coil winding into the die casting fixture, and then, insulating the heat dissipation material A mixture with the hardener is poured into the mold fixture and the coil winding is heated and solidified. Finally, the coil winding of the cured molding is demolded from the mold casting fixture to form a coil module having a heat dissipation function.

Embodiments of the present invention further provide a slotless motor coil module, the coil module including a coil winding and an insulating heat dissipation layer, wherein the coil winding includes a plurality of phase windings, each phase winding includes a plurality of loop coils, and the insulation The heat dissipation layer covers the coil windings, whereby the insulating heat dissipation layer conducts thermal energy of the coil windings to increase heat dissipation of the coil windings.

In summary, the slotless motor coil module and the manufacturing method thereof provided by the embodiments of the present invention can effectively fix the coil windings on the inner side of the stator core to prevent the multi-phase windings from interfering with each other. The coil winding is covered by the insulating heat dissipation layer, which not only increases the fixing effect, but also can transmit the thermal energy of the coil winding and increase the heat dissipation of the coil winding, thereby using the slotless motor of the coil module of the invention to operate quite quietly and It has good heat dissipation and can be used in motor units of various speeds.

The detailed description of the present invention and the accompanying drawings are to be understood by the claims The scope is subject to any restrictions.

[First Embodiment]

Referring to FIG. 2A, FIG. 2A is a flow chart showing the steps of the first embodiment of the method for manufacturing the slotless motor coil module of the present invention. Please also refer to FIG. 2B, which is an exploded perspective view of a coil module using the manufacturing method of the slotless motor coil module of the present invention.

As shown in FIGS. 2A to 2B, the manufacturing method of the slotless motor coil module of the present invention includes, first, preparing a coil winding 240 (S201) by a manual or electric winding machine, the coil winding 240 having a plurality of The phase windings, the number of the plurality of phase windings are not limited to the angle therebetween, and the plurality of phase windings have an accurate and good arrangement regardless of whether the coil windings 240 are prepared by a manual or electric winding machine.

Next, a die casting fixture 27 is prepared. The mold fixture 27 includes a housing 271 and a cylinder 275. The housing 271 has a receiving portion 273. The cylinder 275 is disposed at the center of the receiving portion 273. (S203).

Next, before inserting the coil winding 240 into the mold fixture 27, the inner side of the mold fixture 27 is coated with a release agent, and the uncured molded coil module 240 produced above is placed in the mold casting. The inside of the accommodating portion 273 of the jig 27 (S205).

After that, the mixture of the insulating heat dissipating material and the hardener is poured into the accommodating portion 273 in which the coil winding 240 is housed (S207), wherein the insulating heat dissipating material may be an electronic insulating heat dissipating resin 5940AS mixed hardener 5940BH, and the mixing ratio thereof may be The ratio of the electronically insulating heat-dissipating resin to the hardener is preferably about 3:7, and the materials and ratios of the above-mentioned mixing are not limited thereto, and the user can vary depending on the material characteristics.

The mold jig 27 is statically set, and after the surface of the mixture of the insulating heat dissipating material and the hardener is uniform and free of bubbles, the mold jig 27 containing the coil winding 240 and the potting mixture is placed in a heating furnace to be baked (S209). To form a cured molded coil module 24. For example, when the heating temperature is about 100 ° C, the heating is continued for about 3 hours, and then the temperature is adjusted to about 150 ° C and heating is continued for about 9 hours.

Finally, the cured coil module 24 and the mold jig 27 are released from the mold (S211) to form a coil module 24 having an insulating heat dissipation layer 247. The insulating heat dissipation layer 247 is a hardened insulating heat dissipating material, and the coil winding 240 is covered by the insulating heat dissipation layer 247, so that the coil windings 240 in the coil module 24 can be accurately positioned and arranged so that the phase windings do not interfere with each other. When applied to the stator in the slotless motor, the effect of enhancing the heat dissipation of the coil winding can be achieved.

[Second embodiment]

Next, the arrangement of the coil windings of the slotless motor coil module of the present invention will be exemplified. Please refer to FIG. 3. FIG. 3A to FIG. 3E are schematic diagrams showing an embodiment of a coil winding of the present invention.

As shown in FIG. 3A, the coil winding 341 includes a plurality of phase windings, for example, including three phase windings, which are an a-phase winding 341a, a b-phase winding 341b, and a c-phase winding 341c, each phase winding including a plurality of toroidal coils 342, For example, four toroidal coils 342 are included, and each of the toroidal coils 342 of each phase winding 341a, 341b or 341c is connected in series. The number of the plurality of phase windings 341a, 341b or 341c and the number of the plurality of toroidal coils 342 of the coil winding 341 can be adjusted according to the design of the user, and is not limited to the one shown in the drawing.

As shown in FIG. 3B, a fixing frame 343 can be prepared by using a silicone mold or the like. The fixing frame 343 includes an annular portion 3431 and a plurality of protruding portions 3433. A plurality of protruding portions 3433 are disposed on the outer side surface 3430 of the annular portion 3431 at equal intervals, and a plurality of spaced grooves 3435 are formed between the plurality of protruding portions 3433.

In one embodiment, the material of the fixed frame 343 is a non-magnetic, non-conductive and high temperature resistant material, such as polycarbonate, which can withstand temperatures of about 150 ° C, and the fixed frame 343 has properties such as toughness and deformation.

As shown in FIG. 3C, the coil winding 341 is wound around the outer side surface 3430 of the fixed frame body 343, and the fixing frame body 343 is used as an in-line tool for the coil winding 341 to form an uncured formed coil winding 341. 3C shows only that the a-phase winding 341a surrounds the fixed frame 343, and each of the toroidal coils 342 is provided with at least one of the plurality of protrusions 3433.

For example, each of the toroidal coils 342 includes a first half coil and a second half coil, wherein the first half coil is disposed in one of the spacing grooves 3435 and the second half coil is disposed in the spaced spacing groove 3435'. In one embodiment, each of the toroidal coils 342 can span a plurality of spaced slots 3435, 3435', such as across four spaced slots 3435, and the first half coil of each toroidal coil 342 and the adjacent toroidal coil 342' The second half of the coil is disposed in the same spacing slot 3435. The number of the plurality of spaced grooves 3435 spanned by each of the toroidal coils 342 can be adjusted according to the number of the plurality of spaced grooves 3435 and the number of the circular coils 342, that is, the plurality of phase windings 341a, 341b in the coil winding 341 of the present invention. Or the angle of the motor between 341c is not limited.

According to the third embodiment of the present invention, the size of the fixed frame 343 determines the size of the coil winding 341, and is designed to match the outer diameter of the rotor core (not shown) of the slotless motor and the stator core (Fig. It is determined by the inner diameter of the unillustrated). The number of the plurality of protruding portions 3433 of the fixed frame 343 is determined by the number of the plurality of magnetic elements on the rotor, the number of the toroidal coils 342, and the angle of the motor between the plurality of phase windings 341a, 341b, and 341c. The fixed frame 343 can elastically design the number of the plurality of protruding portions 3433 according to the angle of the motor distributed by the coil winding 341, and is not limited by the number of fixed slots. In addition to this, the fixed frame 343 allows the plurality of loop coils 342 of the coil winding 341 to be accurately and fixedly distributed inside the stator core.

FIG. 3C shows only that the a-phase winding 341a is surrounded by the fixed frame 343. In actual implementation, the coil winding 341 can be distributed as shown in FIG. 3D and FIG. 3E. FIG. 3D shows a coil 341' which is completed by a non-uniform distribution in which the a-phase winding 341a is first wound around the fixed frame 343, and then the b-phase winding is sequentially wound. 341b and c-phase winding 341c, such a coil winding distribution method, will cause a three-phase voltage imbalance due to uneven magnetic field distribution.

Fig. 3E shows a coil winding 341", which is completed by uniform distribution. The first loop coil of the a-phase winding 341a is wound around the fixed frame 343, and then sequentially wound. The first toroidal coil of the b-phase winding 341b and the c-phase winding 341c is then repeatedly wound around the a-phase winding 341a, the b-phase winding 341b, and the second-phase coil of the c-phase winding 341c, and finally sequentially wound up. The third toroid of the a-phase winding 341a, the b-phase winding 341b, and the c-phase winding 341c. Thereby, when the distribution of the different coil windings 341', 341" described above is applied to the slotless motor, different magnetic field distribution characteristics can be obtained.

In summary, the present invention uses a die-casting fixture to solidify a coil winding to form an insulating heat-dissipating material outside the coil winding, which not only enhances heat dissipation, but also effectively fixes the coil on the inner side of the stator core. Thereby, the slotless motor using the coil module manufactured by the present invention has good heat dissipation during operation and good stability, and is suitable for motor devices of various operating speeds.

The above description is only an embodiment of the present invention, and is not intended to limit the scope of the invention.

10. . . Motor

11. . . Rotor core

13. . . magnet

15. . . Stator core

17. . . Groove

twenty four. . . Coil module

240, 341, 341', 341"... coil winding

342, 342'. . . Toroidal coil

341a. . . Phase a winding

341b‧‧‧b phase winding

3341c‧‧‧c phase winding

343‧‧‧Fixed frame

3430‧‧‧Front frame outer side

3431‧‧‧Rings

3433‧‧‧Protruding

3435, 3435'‧‧‧ spacer

247‧‧‧Insulated heat sink

27‧‧‧Mold casting fixture

271‧‧‧Shell

273‧‧‧ 容部

275‧‧‧Cylinder

Figure 1 is a schematic view of a conventional motor.

2A is a flow chart of a first embodiment of a method of manufacturing a slotless motor coil module of the present invention.

2B is a schematic view showing a first embodiment of the slotless motor coil module of the present invention.

3A to 3E are schematic views showing a second embodiment of a coil winding in the slotless motor coil module of the present invention.

S201~S211. . . Example steps for manufacturing a coil module

Claims (8)

A manufacturing method of a slotless motor coil module, comprising: preparing a coil winding, wherein the coil winding comprises a plurality of phase windings; preparing a die casting fixture; and placing the coil winding into the die casting fixture; A mixture of the insulating heat dissipating material and the hardener is poured into the mold fixture, and the insulating heat dissipating material and the hardener are 5940AS and 5940BH, respectively, and the mixing ratio is 3:7; the coil winding is heated and cured, and the heating temperature is Heating at 100 ° C for 3 hours, then adjusting the temperature to 150 ° C for 9 hours; and detaching the cured coiled wire from the die-casting fixture to form a coil module having an insulating heat dissipation layer, And the insulating heat dissipation layer covers the coil winding. The method for manufacturing a slotless motor coil module according to claim 1, wherein the insulating heat dissipating material is a resin. The method for manufacturing a slotless motor coil module according to claim 1, wherein before the coil winding is placed in the mold fixture, the method further comprises applying a release agent to the mold fixture. Inner side. The method for manufacturing a slotless motor coil module according to claim 1, wherein the method for preparing the coil winding is prepared by an electric winding machine. The method for manufacturing a slotless motor coil module according to claim 1, wherein the method for preparing the coil winding is prepared by manually fixing on a fixed frame. The method for manufacturing a slotless motor coil module according to claim 5, wherein the insulating heat dissipation layer covers the coil winding and the fixing frame. The method for manufacturing a slotless motor coil module according to claim 1, wherein the heating and curing the coil winding is performed by placing the mold fixture and the coil winding in a heating furnace. A slotless motor coil module comprising: a coil winding, the coil winding comprising a plurality of phase windings, wherein each phase winding comprises a plurality of loop coils; and an insulating heat dissipation layer covering the coil winding Thereby, the insulating heat dissipation layer conducts heat energy of the coil winding to increase heat dissipation of the coil winding, wherein the insulating heat dissipation layer is a mixture of an insulating heat dissipating material and a hardener, and the insulating heat dissipating material and the hardener are respectively 5940AS And 5940BH, and the mixing ratio is 3:7, and the insulating heat dissipation layer is formed by heat-curing and molding the coil winding through the mold jig, and in the process of heat curing molding, the heating temperature is first at 100 ° C and continues Heat for 3 hours, then adjust the temperature to 150 ° C and continue heating for 9 hours.