TWI852894B - Winding structure of stator or rotor for motor, generator or electromagnetic conveyor belt - Google Patents
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- 238000004804 winding Methods 0.000 title claims abstract description 158
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 8
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Abstract
Description
本發明係為馬達、發電機或電磁輸送帶之定子或轉子之繞組結構,尤指一種至少包含複數個被繞線單元,且將複數組不同電流相位之複數組電磁線圈分組繞設在至少一被繞線單元上,使該被繞線單元可合成出理想的磁場波形或電壓波形,達到提升效能、節省製造成本、節省電力及綠色環保功效之繞組結構。The present invention is a winding structure for a stator or rotor of a motor, a generator or an electromagnetic conveyor, and in particular, refers to a winding structure which comprises at least a plurality of winding units, and a plurality of electromagnetic coils with a plurality of different current phases are wound in groups on at least one winding unit, so that the winding unit can synthesize an ideal magnetic field waveform or voltage waveform, thereby achieving the effect of improving performance, saving manufacturing costs, saving electricity and being green and environmentally friendly.
按目前常見的各種馬達(傳統定子馬達、軸向磁通馬達或線性馬達等各式馬達)、發電機(傳統定子發電機、軸向磁通無鐵心發電機等各式發電機)或電磁輸送帶(藉由控制定子繞組之電流,使其產生之磁場吸引、運送帶有鐵磁性之物質)之定子或轉子上之繞組結構,其主要分為集中式繞組與分佈式的繞組(或稱分散式繞組)兩種結構。前述繞組是指由複數組電磁線圈(可為多匝電磁線圈結構、單匝電磁線圈結構或包括多匝電磁線圈與單匝電磁線圈之結構)構成一相或整個電磁電路的組合。According to the winding structures on the stator or rotor of various common motors (traditional stator motors, axial flux motors, linear motors, etc.), generators (traditional stator generators, axial flux coreless generators, etc.) or electromagnetic conveyors (by controlling the current of the stator windings to generate a magnetic field to attract and transport ferromagnetic materials), they are mainly divided into two structures: concentrated windings and distributed windings (or decentralized windings). The aforementioned windings refer to a combination of multiple sets of electromagnetic coils (which can be multi-turn electromagnetic coil structures, single-turn electromagnetic coil structures, or structures including multi-turn electromagnetic coils and single-turn electromagnetic coils) to form a phase or the entire electromagnetic circuit.
以傳統馬達定子為例,集中式繞組的電磁線圈僅繞在定子的一齒上,沒有跨齒的行為,每組電磁線圈之間為獨立不會交錯,其優點在於電磁線圈的無效端部非常短,可減少導線用量,且可降低電磁線圈電阻、減少銅耗、降低製造成本、縮短製造週期(容易製造)。然而,該集中式繞組具有一大缺點,主要是電機的繞組因數減小,定子磁動勢中諧波含量增加及定子齒、槽對磁場分佈的影響增大,使電機的脈動轉矩增大,也就是說,由於集中式繞組的電機的反電動勢電壓呈梯形曲線,因此該集中式繞組的電機可以產生更大的扭矩,但同時會產生更多的諧波導致更大的損耗和NVH (Noise、Vibration、Harshness,即噪音、振動以及粗糙度) 問題,因此集中式繞組僅適用於無須考量噪音和振動,且僅需考量製造成本的馬達,例如換向器式電動機(包括直流電機和通用電動機)的激磁線圈以及單相罩極式凸極電動機的主極繞組都採用集中式繞組。Taking the traditional motor stator as an example, the electromagnetic coil of the centralized winding is only wound around one tooth of the stator, and there is no cross-tooth behavior. Each set of electromagnetic coils is independent and will not be staggered. The advantage is that the ineffective end of the electromagnetic coil is very short, which can reduce the amount of wire used, and can reduce the resistance of the electromagnetic coil, reduce copper loss, reduce manufacturing costs, and shorten the manufacturing cycle (easy to manufacture). However, the centralized winding has a major disadvantage, which is that the winding factor of the motor is reduced, the harmonic content in the stator magnetomotive force is increased, and the influence of the stator teeth and slots on the magnetic field distribution is increased, which increases the pulsating torque of the motor. In other words, since the back electromotive force voltage of the motor with centralized winding is a trapezoidal curve, the motor with centralized winding can generate greater torque, but at the same time it will generate more harmonics, resulting in greater losses and NVH (Noise, Vibration, Harshness). Therefore, centralized windings are only suitable for motors where noise and vibration do not need to be considered and only the manufacturing cost needs to be considered. For example, the excitation coils of commutator motors (including DC motors and general motors) and the main pole windings of single-phase shaded-pole salient-pole motors all use centralized windings.
而分佈式繞組為最普遍應用的繞組結構,分佈式繞組的電磁線圈會跨越定子的齒部,因此會有電磁線圈交疊或交錯的情況,因此其缺點在於電磁線圈的無效端部較長、導線用量多、電磁線圈電阻高、銅耗大、效率降低、定子槽滿率低,且先繞的電磁線圈會擋住可繞線空間致使後繞的電磁線圈無法使用,由於分佈式繞組的製造工序複雜且製造時間長(不容易製造),故其製造成本高。然而,分佈式繞組主要優點在於定子磁動勢中的諧波含量減少與定子齒、槽對磁場分佈的影響減小,使電機的脈動電壓富度減小,也就是說,分佈式繞組可透過複數組電磁線圈在每一定子的齒部端部上合成出使用者所需且最理想的磁場波形,以減少馬達的噪音和振動。The distributed winding is the most commonly used winding structure. The electromagnetic coils of the distributed winding will cross the teeth of the stator, so there will be overlap or staggered electromagnetic coils. Therefore, its disadvantages are that the ineffective ends of the electromagnetic coils are longer, the amount of wire used is large, the electromagnetic coil resistance is high, the copper loss is large, the efficiency is reduced, the stator slot fill rate is low, and the electromagnetic coils wound first will block the winding space, making the electromagnetic coils wound later unusable. Since the manufacturing process of the distributed winding is complicated and the manufacturing time is long (not easy to manufacture), its manufacturing cost is high. However, the main advantage of distributed winding is that the harmonic content in the stator magnetic force is reduced and the influence of the stator teeth and slots on the magnetic field distribution is reduced, so that the pulse voltage richness of the motor is reduced. In other words, the distributed winding can synthesize the user's required and most ideal magnetic field waveform at the end of each stator tooth through multiple sets of electromagnetic coils to reduce the noise and vibration of the motor.
經本案發明人長時間研究傳統分佈式繞組的結構後,發現其在傳統馬達定子上進行合成磁場波形時具有以下缺點:After a long period of research on the structure of traditional distributed windings, the inventors of this case found that it has the following disadvantages when synthesizing magnetic field waveforms on traditional motor stators:
第一,對於同一組電磁線圈內的複數個齒部,由於每個齒部與該組電磁線圈的相對位置皆不同,因此該組電磁線圈對每個齒部的感應磁場的影響力不同,離該電磁線圈愈遠的齒部,其受到該電磁線圈感應磁場的影響力會大幅降低,而造成馬達整體效率低下,且不易設計出理想的合成磁場。First, for multiple teeth in the same set of electromagnetic coils, since the relative position of each tooth to the set of electromagnetic coils is different, the influence of the electromagnetic coil on the induced magnetic field of each tooth is different. The farther the tooth is from the electromagnetic coil, the less influence it will receive from the induced magnetic field of the electromagnetic coil, resulting in low overall motor efficiency and difficulty in designing an ideal synthetic magnetic field.
第二,對同一個齒部來說,各組電磁線圈在該齒部的磁力線方向上與該齒部端部的距離皆不同(先繞設的電磁線圈距離該齒部的端部較遠,後繞設的電磁線圈距離該齒部的端部較近),距離越遠的電磁線圈對該齒部端部的感應磁場的影響力大幅降低,而造成馬達整體效率低下,且不易設計出理想的合成磁場。Second, for the same tooth, the distances between each set of electromagnetic coils and the end of the tooth in the direction of the magnetic field lines of the tooth are different (the electromagnetic coils wound first are farther from the end of the tooth, and the electromagnetic coils wound later are closer to the end of the tooth). The influence of the electromagnetic coils that are farther away on the induced magnetic field at the end of the tooth is greatly reduced, resulting in low overall motor efficiency and difficulty in designing an ideal synthetic magnetic field.
為此,本案發明人特針對前揭集中式繞組與分佈式繞組所存在之問題及缺點加以研究,而發明本案。To this end, the inventor of this case has studied the problems and shortcomings of the aforementioned centralized winding and distributed winding and invented this case.
本發明之目的,係提供一種可應用於各式馬達、發電機或電磁輸送帶之定子或轉子上之創新繞組結構,其定子與轉子為作相對運動之元件,且其定子或轉子上至少包含複數個被繞線單元,前述至少一被繞線單元之外表面上係繞設複數組電磁線圈,在該被繞線單元上之複數組電磁線圈係具有不同電流相位,其透過將複數組不同電流相位之複數組電磁線圈繞設在同一被繞線單元的外表面上,使該被繞線單元兼具有集中式繞組結構的無效端部非常短、可減少導線用量、減少銅耗、降低製造成本、容易製造的優點,以及分佈式繞組結構可合成磁場波形(例如馬達、磁力輸送帶、電磁鐵、磁阻制動器等)或電壓波形(例如發電機)的優點,以達到提升電磁轉換效率、節省製造成本、節省電力及綠色環保之功效。The purpose of the present invention is to provide an innovative winding structure applicable to the stator or rotor of various motors, generators or electromagnetic conveyors, wherein the stator and the rotor are elements that move relative to each other, and the stator or the rotor at least comprises a plurality of winding units, and a plurality of sets of electromagnetic coils are wound on the outer surface of at least one of the winding units, and the plurality of sets of electromagnetic coils on the winding unit have different current phases. It is arranged on the outer surface of the same wound unit, so that the wound unit has the advantages of a centralized winding structure, that is, the ineffective end is very short, the amount of wire used, the copper loss, the manufacturing cost, and the ease of manufacturing, and the advantages of a distributed winding structure, that is, the magnetic field waveform (such as a motor, a magnetic conveyor belt, an electromagnetic iron, a magnetic resistance brake, etc.) or a voltage waveform (such as a generator), so as to achieve the effects of improving electromagnetic conversion efficiency, saving manufacturing costs, saving electricity, and green environmental protection.
值得一提的是,以馬達定子為例,本發明的特色在於定子的複數個被繞線單元中,至少一被繞線單元(例如傳統定子的齒部或本案發明人創新研發之彎曲式鐵心)的外表面有複數組電磁線圈包覆於其上,且相鄰被繞線單元之間並無共用的電磁線圈,因此被繞線單元與每組電磁線圈之間的距離非常貼近且相對位置一致,每一組電磁線圈對該被繞線單元的感應磁場的影響力皆非常相近且非常高,如此即可提升馬達整體效率,且更容易設計出理想的合成磁場,解決傳統分佈式繞組結構之同一組電磁線圈內對不同的齒部的磁場的影響力不同所造成的馬達整體效率低下及不易設計出理想的合成磁場的問題。It is worth mentioning that, taking the motor stator as an example, the feature of the present invention is that among the multiple winding units of the stator, at least one winding unit (such as the teeth of the conventional stator or the curved iron core innovatively developed by the inventor of the present invention) has multiple sets of electromagnetic coils wrapped on its outer surface, and there is no common electromagnetic coil between adjacent winding units, so the distance between the winding unit and each set of electromagnetic coils is very close. And the relative positions are consistent, and the influence of each set of electromagnetic coils on the induced magnetic field of the wound unit is very similar and very high, so that the overall efficiency of the motor can be improved, and it is easier to design an ideal synthetic magnetic field, solving the problem of low overall motor efficiency and difficulty in designing an ideal synthetic magnetic field caused by the different influences of the magnetic fields of different teeth in the same set of electromagnetic coils in the traditional distributed winding structure.
更進一步地說,本發明不只能用於一體成型的定子或轉子(例如傳統定子的馬達或發電機、定子為單側相連的軸向磁通馬達或發電機等),更能運用在定子或轉子為獨立被繞線單元的馬達或發電機上(例如定子為兩側皆有端部的軸向磁通馬達或發電機,或具有低反磁化因子之彎曲式鐵心的馬達、發電機或電磁輸送帶),若在具有獨立的複數個被繞線單元之定子或轉子上使用傳統分佈式繞組的話,由於同一組電磁線圈需要跨越複數個被繞線單元,因此勢必得將所有被繞線單元組成一體後才能設置繞組,且因每組電磁線圈需要佔據大量空間(如同傳統定子齒部之間凹陷出空間逐漸變大的容置槽以設置電磁線圈)而使得被繞線單元之間的距離變大或被繞線單元的截面積變小,此時如果被繞線單元為彎曲的形狀的話,將更難以把電磁線圈設置在彎曲的空間路徑上的同時還要跨越複數個被繞線單元。Furthermore, the present invention can be applied not only to integrally formed stators or rotors (e.g., motors or generators with conventional stators, axial flux motors or generators with stators connected on one side, etc.), but also to motors or generators with stators or rotors being independent winding units (e.g., axial flux motors or generators with stators having ends on both sides, or motors, generators or electromagnetic conveyors with bent cores having low demagnetization factors). If conventional distributed windings are used on stators or rotors having independent multiple winding units, the The same set of electromagnetic coils needs to span across multiple winding units, so all the winding units must be assembled into one before the winding can be set. Moreover, since each set of electromagnetic coils needs to occupy a large amount of space (just like the traditional stator teeth are recessed with gradually larger space to set the electromagnetic coils), the distance between the winding units becomes larger or the cross-sectional area of the winding units becomes smaller. At this time, if the winding units are curved, it will be more difficult to set the electromagnetic coils on the curved space path while spanning multiple winding units.
相反地,若在獨立的複數個被繞線單元上使用本發明的繞組結構的話,由於同一組電磁線圈不需要跨越複數個被繞線單元,因此得將被繞線單元各別繞線、模組化後再組成一個馬達、發電機或電磁輸送帶之定子或轉子,有利於各種容易、快速且大量生產的自動化製程或維修以降低人力與時間成本,且因每組電磁線圈與被繞線單元之間的距離十分貼近而不需要大量空間,故得以縮小被繞線單元之間的距離或提高被繞線單元的截面積,同時利用本發明的繞組結構能於任意彎曲形狀的被繞線單元上或於有部分位置需要設置固定支架的被繞線單元上輕易地設置電磁線圈,並使馬達、發電機或電磁輸送帶之定子或轉子能享有如同集中式繞組的優點的同時,也能如同分佈式繞組一樣合成出理想的磁場波形或電壓波形。On the contrary, if the winding structure of the present invention is used on a plurality of independent wound units, since the same set of electromagnetic coils does not need to cross a plurality of wound units, the wound units need to be wound separately and modularized to form a motor, generator or stator or rotor of an electromagnetic conveyor belt, which is conducive to various easy, fast and mass production automated processes or maintenance to reduce labor and time costs. In addition, since the distance between each set of electromagnetic coils and the wound units is very close, there is no need to A large amount of space is not required, so the distance between the wound units can be shortened or the cross-sectional area of the wound units can be increased. At the same time, the winding structure of the present invention can be used to easily install electromagnetic coils on wound units of any curved shape or on wound units where a fixed bracket is required to be installed at some positions, so that the stator or rotor of the motor, generator or electromagnetic conveyor belt can enjoy the advantages of concentrated winding and synthesize an ideal magnetic field waveform or voltage waveform like distributed winding.
再者,本發明對於同一個被繞線單元來說,各組電磁線圈在該被繞線單元的磁力線方向上與該被繞線單元端部的距離皆非常相近且差異小,如此每一組電磁線圈對該被繞線單元端部的感應磁場的影響力皆非常大,可提升馬達、發電機或電磁輸送帶之整體效率,且更容易設計出理想的合成磁場波形或電壓波形,解決傳統分佈式繞組結構之各組電磁線圈在同一齒部的磁力線方向上與該齒部端部的距離皆不同所造成的馬達、發電機或電磁輸送帶整體效率低下及不易設計出理想的合成磁場波形或電壓波形的問題。Furthermore, for the same wound unit, the distances between each set of electromagnetic coils and the end of the wound unit in the direction of the magnetic field lines of the wound unit are very close and the difference is small. Thus, each set of electromagnetic coils has a very large influence on the induced magnetic field at the end of the wound unit, which can improve the overall efficiency of the motor, generator or electromagnetic conveyor belt, and it is easier to design an ideal synthetic magnetic field waveform or voltage waveform, thereby solving the problem that the overall efficiency of the motor, generator or electromagnetic conveyor belt is low and it is difficult to design an ideal synthetic magnetic field waveform or voltage waveform because the distances between each set of electromagnetic coils in the direction of the magnetic field lines of the same tooth are different from the end of the tooth in the traditional distributed winding structure.
此外,本發明可藉由改變被繞線單元上各組電磁線圈的匝數、層數、線徑、寬度、厚度、材質等參數,自由且非常容易設計出所需的合成磁場波形或電壓波形,且沒有傳統分佈式繞組結構之無效端部銅損的問題。相對於傳統分佈式繞組結構,本發明由於各組電磁線圈沒有跨越多個被繞線單元,所以製造容易,且可透過各種自動化製程快速且大量的製造各種馬達、發電機或電磁輸送帶之定子或轉子。In addition, the present invention can freely and easily design the required synthetic magnetic field waveform or voltage waveform by changing the number of turns, number of layers, wire diameter, width, thickness, material and other parameters of each set of electromagnetic coils on the winding unit, and there is no problem of ineffective end copper loss of the traditional distributed winding structure. Compared with the traditional distributed winding structure, the present invention is easy to manufacture because each set of electromagnetic coils does not cross multiple winding units, and various motors, generators or stators or rotors of electromagnetic conveyors can be manufactured quickly and in large quantities through various automated processes.
為達前述目的,本發明之用於馬達、發電機或電磁輸送帶之定子或轉子之繞組結構,至少包含複數個被繞線單元,前述至少一被繞線單元之外表面上係繞設複數組電磁線圈,該被繞線單元之複數組電磁線圈係於該被繞線單元的磁力線的法線方向上分層設置於該被繞線單元的外表面上,且前述複數組電磁線圈之相鄰的每一組電磁線圈係具有不同的電流相位,如此即可在馬達、發電機或電磁輸送帶之定子或轉子上形成複數組可設計磁場波形或電壓波形之繞組。To achieve the above-mentioned purpose, the winding structure of the stator or rotor of the motor, generator or electromagnetic conveyor of the present invention comprises at least a plurality of winding units, a plurality of sets of electromagnetic coils are wound on the outer surface of the at least one winding unit, the plurality of sets of electromagnetic coils of the winding unit are arranged in layers on the outer surface of the winding unit in the normal direction of the magnetic field lines of the winding unit, and each adjacent set of electromagnetic coils of the plurality of sets of electromagnetic coils has a different current phase, so that a plurality of sets of windings with designable magnetic field waveforms or voltage waveforms can be formed on the stator or rotor of the motor, generator or electromagnetic conveyor.
前述不同的電流相位係指在一時間點(瞬間),其電流之大小或方向不同,而所謂電流方向係指,我們從一線圈之其中一端(或稱頭部)以順時針方向繞線至另一端(或稱尾部),若改變電流是從頭部或是尾部流入將會改變電流方向,或者若改變以順時針或逆時針方向繞線也會改變電流方向。而產生不同電流相位之方式有,例如一般之交流電,或大小或方向不同之直流電,或使用電容或驅動器改變或控制其電流之大小或方向等任何方式皆可使不同組的電磁線圈具有不同的電流相位。The different current phases mentioned above refer to the different magnitude or direction of the current at a certain point in time (instant), and the so-called current direction means that we wind the wire from one end (or head) of a coil in a clockwise direction to the other end (or tail). If we change whether the current flows from the head or tail, the current direction will change, or if we change the winding direction to clockwise or counterclockwise, the current direction will also change. There are ways to generate different current phases, such as general alternating current, or direct current of different magnitude or direction, or using capacitors or drivers to change or control the magnitude or direction of the current. Any method can make different groups of electromagnetic coils have different current phases.
本發明之用於馬達、發電機或電磁輸送帶之定子或轉子之繞組結構之另一實施例,其至少包含複數個被繞線單元,前述至少一被繞線單元之外表面上係繞設複數組電磁線圈,該被繞線單元之複數組電磁線圈係於該被繞線單元的磁力線方向上間隔繞設於前述被繞線單元的外表面上,且前述複數組電磁線圈之相鄰的每一組電磁線圈係具有不同的電流相位,如此即可在馬達、發電機或電磁輸送帶之定子或轉子上形成複數組可設計磁場波形或電壓波形之繞組。Another embodiment of the winding structure of the stator or rotor of the motor, generator or electromagnetic conveyor of the present invention comprises at least a plurality of winding units, a plurality of sets of electromagnetic coils are wound on the outer surface of at least one of the winding units, the plurality of sets of electromagnetic coils of the winding unit are wound on the outer surface of the winding unit at intervals in the direction of the magnetic field lines of the winding unit, and each adjacent set of electromagnetic coils of the plurality of sets of electromagnetic coils has a different current phase, so that a plurality of sets of windings with designable magnetic field waveforms or voltage waveforms can be formed on the stator or rotor of the motor, generator or electromagnetic conveyor.
本發明之用於馬達、發電機或電磁輸送帶之定子或轉子之繞組結構之另一實施例,其至少包含複數個被繞線單元,前述至少一被繞線單元之外表面上係繞設複數組電磁線圈,前述複數組電磁線圈係於前述被繞線單元的磁力線的法線方向上分層設置於前述被繞線單元的外表面上,且前述每一分層係具有至少一組電磁線圈,前述具有二組以上電磁線圈之分層位置,其每組電磁線圈係於前述被繞線單元的磁力線方向上間隔繞設於前述被繞線單元的外表面上, 且前述分層相鄰與間隔相鄰的每一組電磁線圈係具有不同的電流相位,如此即可在馬達、發電機或電磁輸送帶之定子或轉子上形成複數組可設計磁場波形或電壓波形之繞組。Another embodiment of the winding structure for the stator or rotor of a motor, a generator or an electromagnetic conveyor of the present invention comprises at least a plurality of winding units, a plurality of sets of electromagnetic coils are wound on the outer surface of the at least one winding unit, the plurality of sets of electromagnetic coils are arranged in layers on the outer surface of the winding unit in the normal direction of the magnetic field lines of the winding unit, and each of the layers has at least one set of electromagnetic coils, and each set of electromagnetic coils is wound on the outer surface of the winding unit at intervals in the direction of the magnetic field lines of the winding unit at the layer position having more than two sets of electromagnetic coils. Furthermore, each set of electromagnetic coils adjacent to each other in layers and adjacent to each other in intervals has a different current phase, so that a plurality of windings with designable magnetic field waveforms or voltage waveforms can be formed on the stator or rotor of a motor, a generator or an electromagnetic conveyor belt.
本發明之馬達、發電機或電磁輸送帶之定子或轉子之繞組結構,前述被繞線單元得為有實體之物(例如各種高磁導率材料、低磁導率材料或非鐵磁性物質)或無實體之空間(例如設置完前述複數組電磁線圈後,將作為治具的被繞線單元抽離,並對複數組電磁線圈以膠合或樹酯成型等方式進行固定)。In the winding structure of the stator or rotor of the motor, generator or electromagnetic conveyor of the present invention, the aforementioned wound unit may be a solid object (e.g., various high magnetic permeability materials, low magnetic permeability materials or non-ferromagnetic materials) or a non-solid space (e.g., after the aforementioned plurality of electromagnetic coils are set, the wound unit used as a jig is removed, and the plurality of electromagnetic coils are fixed by gluing or resin molding).
本發明之馬達、發電機或電磁輸送帶之定子或轉子之繞組結構,前述複數組電磁線圈之每組電磁線圈得設置有絕緣單元,該絕緣單元得為包覆於前述電磁線圈之內、外表面之絕緣紙或絕緣膜,或得為密封前述電磁線圈之絕緣膠等可用於將前述電磁線圈進行隔離絕緣之材料。In the winding structure of the stator or rotor of the motor, generator or electromagnetic conveyor of the present invention, each of the plurality of electromagnetic coils may be provided with an insulating unit, and the insulating unit may be an insulating paper or insulating film coated on the inner and outer surfaces of the electromagnetic coil, or may be an insulating glue that seals the electromagnetic coil, etc., which can be used to isolate and insulate the electromagnetic coil.
本發明之馬達、發電機或電磁輸送帶之定子或轉子之繞組結構,其特殊之處在於,前述複數組電磁線圈之每組電磁線圈得由各種線徑、寬度、厚度、材質之絕緣導線繞設而成,其得為單匝線圈結構或多匝線圈結構,且前述每組電磁線圈可繞設不同的層數及厚度,並且不需要所有被繞線單元上皆設置複數組電磁線圈,能以部分被繞線單元設置一組電磁線圈及部分被繞線單元設置複數組電磁線圈的方式組成整個繞組,而具有複數組電磁線圈之被繞線單元上之複數組電磁線圈的順序不需要完全一致,如此即可在每個被繞線單元上,透過使用不同類形(即不同的匝數、層數、線徑、寬度、厚度、材質)的每組電磁線圈,以改變各組電磁線圈的電感值(更精確地說係阻抗值),並改變合成磁場波形或電壓波形,達到設計所需波形之功效。The winding structure of the stator or rotor of the motor, generator or electromagnetic conveyor of the present invention is special in that each of the plurality of electromagnetic coils may be wound with insulating wires of various wire diameters, widths, thicknesses and materials, and may be a single-turn coil structure or a multi-turn coil structure, and each of the electromagnetic coils may be wound with different layers and thicknesses, and it is not necessary to set a plurality of electromagnetic coils on all wound units, and one electromagnetic coil may be set on some wound units and one electromagnetic coil may be set on some wound units. The unit is provided with a plurality of sets of electromagnetic coils to form the entire winding, and the sequence of the plurality of sets of electromagnetic coils on the wound unit having the plurality of sets of electromagnetic coils does not need to be completely consistent. In this way, on each wound unit, by using each set of electromagnetic coils of different types (i.e., different numbers of turns, numbers of layers, wire diameters, widths, thicknesses, and materials), the inductance value (more precisely, the impedance value) of each set of electromagnetic coils can be changed, and the synthetic magnetic field waveform or voltage waveform can be changed to achieve the effect of the waveform required by the design.
為了更進一步瞭解本發明,該最佳之馬達、發電機或電磁輸送帶之定子或轉子之繞組結構之實施方式如圖式1~12所示,至少包含:In order to further understand the present invention, the best implementation of the winding structure of the stator or rotor of the motor, generator or electromagnetic conveyor is shown in Figures 1 to 12, which at least includes:
複數個被繞線單元1,前述至少一被繞線單元1之外表面上係繞設複數組電磁線圈2,在該被繞線單元1上之複數組電磁線圈2係具有不同電流相位,前述被繞線單元1得為有實體之物(例如各種高磁導率材料、低磁導率材料或非鐵磁性物質)或無實體之空間(例如設置完複數組電磁線圈後,將作為治具的被繞線單元抽離,並對複數組電磁線圈以膠合或樹酯成型等方式進行固定)。如圖2、4、6、7所示,前述複數組電磁線圈2之每組電磁線圈得由各種線徑、寬度、厚度、材質之絕緣導線或非圓形絕緣導線繞設而成,其得為單匝線圈結構或多匝線圈結構。如圖3所示,前述複數組電磁線圈2之每組電磁線圈可繞設不同的層數及厚度,只要其為同一電流相位之一組電磁線圈,均無不可。A plurality of wound units 1, a plurality of electromagnetic coils 2 are wound on the outer surface of at least one of the wound units 1, the plurality of electromagnetic coils 2 on the wound unit 1 have different current phases, the wound unit 1 can be a solid object (for example, various high magnetic permeability materials, low magnetic permeability materials or non-ferromagnetic substances) or a non-solid space (for example, after the plurality of electromagnetic coils are set, the wound unit used as a fixture is pulled out, and the plurality of electromagnetic coils are fixed by gluing or resin molding). As shown in Figures 2, 4, 6, and 7, each of the plurality of electromagnetic coils 2 may be wound with insulating wires or non-circular insulating wires of various diameters, widths, thicknesses, and materials, and may be a single-turn coil structure or a multi-turn coil structure. As shown in Figure 3, each of the plurality of electromagnetic coils 2 may be wound with different layers and thicknesses, as long as they are a set of electromagnetic coils with the same current phase.
如圖1~4所示,前述複數組電磁線圈2之每組電磁線圈得設置有絕緣單元20,該絕緣單元20得為包覆於前述每組電磁線圈之內、外表面之絕緣紙或絕緣膜,或得為密封前述每組電磁線圈之絕緣膠,只要是可用於將前述複數組電磁線圈2之每組電磁線圈進行隔離絕緣之材料,均無不可。前述被繞線單元1得為各種形狀或形式之結構,例如傳統定子之各種齒部結構或具有低反磁化因子之彎曲式鐵心(如圖8所示),且該被繞線單元1之截面形狀亦不受限制,端視實際使用需求而定,均無不可。前述具有低反磁化因子之彎曲式鐵心,其兩端部係相互靠近,如此即可使鐵心之空氣磁路的長度相對於鐵心磁路的長度之比值最小化,以提升電轉磁效率及馬達或電磁輸送帶之動力輸出效率。As shown in Figs. 1 to 4, each of the plurality of electromagnetic coils 2 may be provided with an insulating unit 20. The insulating unit 20 may be an insulating paper or insulating film covering the inner and outer surfaces of each of the plurality of electromagnetic coils, or may be an insulating glue sealing each of the plurality of electromagnetic coils. Any material may be used to isolate and insulate each of the plurality of electromagnetic coils 2. The wound unit 1 may be a structure of various shapes or forms, such as various tooth structures of a conventional stator or a bent iron core with a low anti-magnetization factor (as shown in Fig. 8), and the cross-sectional shape of the wound unit 1 is not limited, and may be determined according to actual use requirements. The two ends of the aforementioned bent core with a low anti-magnetization factor are close to each other, so that the ratio of the length of the air magnetic circuit of the core to the length of the core magnetic circuit can be minimized, thereby improving the electromagnetism efficiency and the power output efficiency of the motor or electromagnetic conveyor belt.
如圖1~4所示,為本發明之第一實施例,前述複數組電磁線圈2之每組電磁線圈2A、2B、2C係於前述被繞線單元1的磁力線的法線方向上分層設置於前述被繞線單元1的外表面上,且前述分層相鄰的每一組電磁線圈2A、2B、2C係具有不同的電流相位,如此即可形成一分層繞組結構。前述分層繞組結構適用於被繞線單元1的長度較短且無彎曲的結構中,例如傳統馬達定子的齒部。當然,前述分層繞組結構亦可用於前述具有低反磁化因子之彎曲式鐵心上,當其設置在彎曲結構時,由於彎曲結構之內側與外側之弧長不一致,在緊密繞設各組電磁線圈2A、2B、2C後,會在彎曲結構之內側呈現明顯的分層結構,而在彎曲結構之外側則會呈現較為分散且不一致的分層分佈、交錯分佈或間隔分佈,需特別強調的是,無論各組電磁線圈2A、2B、2C在彎曲結構之外側呈現何種分層態樣,皆不會影響到本發明之繞組結構之合成磁場波形或電壓波形之功效。As shown in Fig. 1 to Fig. 4, it is the first embodiment of the present invention, each set of electromagnetic coils 2A, 2B, 2C of the plurality of sets of electromagnetic coils 2 is arranged in layers on the outer surface of the winding unit 1 in the normal direction of the magnetic field lines of the winding unit 1, and each set of electromagnetic coils 2A, 2B, 2C adjacent to each other in layers has a different current phase, so that a layered winding structure can be formed. The layered winding structure is suitable for a structure in which the length of the winding unit 1 is short and there is no bend, such as the teeth of a conventional motor stator. Of course, the aforementioned layered winding structure can also be used on the aforementioned bent core with a low anti-magnetization factor. When it is set on the bent structure, due to the inconsistency of the arc lengths of the inner and outer sides of the bent structure, after the electromagnetic coils 2A, 2B, and 2C are tightly wound, an obvious layered structure will appear on the inner side of the bent structure, and The outer side of the curved structure will present a more dispersed and inconsistent layered distribution, staggered distribution or spaced distribution. It should be particularly emphasized that no matter what layered state each set of electromagnetic coils 2A, 2B, 2C presents on the outer side of the curved structure, it will not affect the effectiveness of the synthetic magnetic field waveform or voltage waveform of the winding structure of the present invention.
如圖5~8所示,為本發明之第二實施例,前述複數組電磁線圈2之每組電磁線圈2D、2E、2F係於前述被繞線單元1的磁力線方向上間隔繞設於前述被繞線單元1的外表面上,且前述間隔相鄰的每一組電磁線圈2D、2E、2F係具有不同的電流相位,如此即可形成一間隔繞組結構。前述間隔繞組結構主要適用於被繞線單元1的長度較長或具有彎曲的結構中,例如前述具有低反磁化因子之彎曲式鐵心(如圖8所示)。該間隔繞組結構之安裝方法可逐一以較寬間隔的方式將各組電磁線圈2D、2E、2F逐一繞設在前述被繞線單元1的外表面上,或可一次將複數組電磁線圈2D、2E、2F同步繞設在前述被繞線單元1的外表面上,端視實際製造需求而定,均無不可。As shown in Figs. 5 to 8, it is a second embodiment of the present invention, each set of electromagnetic coils 2D, 2E, 2F of the plurality of sets of electromagnetic coils 2 is intermittently wound on the outer surface of the winding unit 1 in the direction of the magnetic field lines of the winding unit 1, and each set of electromagnetic coils 2D, 2E, 2F adjacent to each other has a different current phase, so that an intermittent winding structure can be formed. The intermittent winding structure is mainly applicable to the structure of the winding unit 1 having a long length or a bend, such as the bent core with a low demagnetization factor (as shown in Fig. 8). The installation method of the spaced winding structure can be to wind each set of electromagnetic coils 2D, 2E, 2F one by one at a wider interval on the outer surface of the aforementioned wound unit 1, or to wind a plurality of sets of electromagnetic coils 2D, 2E, 2F simultaneously on the outer surface of the aforementioned wound unit 1 at one time, depending on the actual manufacturing requirements.
如圖9所示,為本發明之第三實施例,前述複數組電磁線圈2係於前述被繞線單元1的磁力線的法線方向上分層設置於前述被繞線單元1的外表面上,且前述每一分層係具有至少一組電磁線圈2G、2H、2I、2J、2K、2L,前述具有二組以上電磁線圈之分層位置(如圖9所示之具有三組電磁線圈2G、2H、2I之分層位置和具有二組電磁線圈2J、2K之分層位置),其每組電磁線圈係於前述被繞線單元1的磁力線方向上間隔繞設於前述被繞線單元1的外表面上, 且前述分層相鄰與間隔相鄰的每一組電磁線圈2G、2H、2I、2J、2K、2L係具有不同的電流相位,如此即可形成一分層間隔複合式繞組結構。前述分層間隔複合式繞組結構主要適用於複數組電磁線圈2之組數較多的被繞線單元1上,此種繞組結構可讓每組電磁線圈之繞線分佈更為平均,且每組電磁線圈可提供較為相近的電磁轉換效率,如此即可更容易設計出理想的合成磁場波形或電壓波形。As shown in FIG. 9 , it is a third embodiment of the present invention. The plurality of electromagnetic coils 2 are arranged in layers on the outer surface of the winding unit 1 in the normal direction of the magnetic field lines of the winding unit 1, and each of the layers has at least one electromagnetic coil 2G, 2H, 2I, 2J, 2K, 2L. The layer positions having more than two electromagnetic coils (such as the layer positions having three electromagnetic coils 2G, 2H, 2I and the layer positions having two electromagnetic coils 2J, 2K as shown in FIG. 9 ) are arranged on the outer surface of the winding unit 1 at intervals in the direction of the magnetic field lines of the winding unit 1. Each of the aforementioned adjacent and spaced electromagnetic coils 2G, 2H, 2I, 2J, 2K, 2L has a different current phase, thus forming a layered and spaced composite winding structure. The aforementioned layered and spaced composite winding structure is mainly applicable to a wound unit 1 with a large number of electromagnetic coils 2. This winding structure allows the winding distribution of each electromagnetic coil to be more even, and each electromagnetic coil can provide a relatively similar electromagnetic conversion efficiency, thus making it easier to design an ideal synthetic magnetic field waveform or voltage waveform.
如圖10~12所示,係為本發明應用於具有彎曲式鐵心之定子之實施例,前述定子係設置有支架10,前述複數彎曲式鐵心係設置於前述定子之支架10上。需特別強調的是,本發明之定子或轉子之複數個被繞線單元中,其並不一定需要於所有的被繞線單元上皆設置複數組電磁線圈,其得以部分被繞線單元設置一組電磁線圈及部分被繞線單元設置各種型式之複數組電磁線圈的方式組成整個繞組(如圖11所示)。且每個具有複數組電磁線圈之被繞線單元,其複數組電磁線圈的排列順序不需要完全一致(如圖12所示),如此即可在每個被繞線單元上,透過使用不同類形(即不同的匝數、層數、線徑、寬度、厚度、材質等)的每組電磁線圈,以改變各組電磁線圈的電感值(或稱阻抗值),並改變合成磁場波形或電壓波形,達到設計所需波形之功效。As shown in FIGS. 10 to 12, the present invention is applied to an embodiment of a stator having a bent core. The stator is provided with a bracket 10, and the plurality of bent cores are provided on the bracket 10 of the stator. It should be particularly emphasized that, among the plurality of winding units of the stator or rotor of the present invention, it is not necessary to provide a plurality of electromagnetic coils on all the winding units. The entire winding can be formed by providing one set of electromagnetic coils on some winding units and providing a plurality of electromagnetic coils of various types on some winding units (as shown in FIG. 11). Furthermore, for each wound unit having a plurality of sets of electromagnetic coils, the arrangement order of the plurality of sets of electromagnetic coils does not need to be completely consistent (as shown in FIG. 12 ). Thus, by using different types (i.e., different numbers of turns, numbers of layers, wire diameters, widths, thicknesses, materials, etc.) of electromagnetic coils for each wound unit, the inductance value (or impedance value) of each set of electromagnetic coils can be changed, and the synthetic magnetic field waveform or voltage waveform can be changed to achieve the desired waveform effect.
表1 Table 1
如表1所示之範例,係為一假設的模型,其係用於進一步說明本發明如何在馬達、發電機或電磁輸送帶之定子或轉子之繞組結構上合成磁場波形或電壓波形,且其並非用於限定本發明之實施態樣。表1為具有12個被繞線單元之馬達定子(分別為被繞線單元①至⑫),並以前述第一實施例的方式從被繞線單元之外表面上分層設置第一組電磁線圈、第二組電磁線圈和第三組電磁線圈(被繞線單元②、④、⑥、⑧、⑩、⑫皆未設置第三組電磁線圈),例如在被繞線單元①上設置有第一組電磁線圈b1、第二組電磁線圈c5與第三組電磁線圈a1,且我們可看出每個被繞線單元的複數組電磁線圈的組數與排列順序可以是不同的。The example shown in Table 1 is a hypothetical model used to further illustrate how the present invention synthesizes a magnetic field waveform or a voltage waveform on the winding structure of the stator or rotor of a motor, a generator or an electromagnetic conveyor, and is not used to limit the implementation of the present invention. Table 1 shows a motor stator having 12 winding units (respectively winding units ① to ⑫), and the first group of electromagnetic coils, the second group of electromagnetic coils and the third group of electromagnetic coils are arranged in layers on the outer surface of the winding units in the manner of the first embodiment (the third group of electromagnetic coils are not arranged on winding units ②, ④, ⑥, ⑧, ⑩, ⑫). For example, the first group of electromagnetic coils b1, the second group of electromagnetic coils c5 and the third group of electromagnetic coils a1 are arranged on the winding unit ①, and we can see that the number of groups and the arrangement order of the multiple groups of electromagnetic coils of each winding unit can be different.
假設此馬達定子之繞組具有3種不同的電流相位,分別為a相、b相與c相,a相之電磁線圈a1代表匝數為1匝,電磁線圈a3為3匝,電磁線圈a5為5匝,且所有a相之電磁線圈皆串聯在一起。我們假設電磁線圈所產生之磁場大小正比於電磁線圈之匝數,則電磁線圈a1、a3、a5之磁場大小之比為1:3:5,而b相與c相之電磁線圈之設定也如同前述a相電磁線圈之設定。則在某一時間點(瞬間)被繞線單元①上之合成磁場波形的大小與方向為,電磁線圈b1在該時間點之電流的大小與方向所產生之磁場的大小與方向,疊加上電磁線圈c5在該時間點之電流的大小與方向所產生之磁場的大小與方向,再疊加上電磁線圈a1在該時間點之電流的大小與方向所產生之磁場的大小與方向,以此類推我們就能得到所有被繞線單元在該時間點之磁場波形的大小與方向。因此藉由改變每個被繞線單元上,透過使用不同類形(即不同的匝數、層數、線徑、寬度、厚度、材質)的每組電磁線圈,以改變各組電磁線圈的電感值(或稱阻抗值),並改變合成磁場波形或電壓波形,達到設計所需波形之功效。Assume that the winding of the motor stator has three different current phases, namely phase a, phase b and phase c. The electromagnetic coil a1 of phase a represents 1 turn, the electromagnetic coil a3 represents 3 turns, the electromagnetic coil a5 represents 5 turns, and all the electromagnetic coils of phase a are connected in series. We assume that the magnitude of the magnetic field generated by the electromagnetic coil is proportional to the number of turns of the electromagnetic coil, then the ratio of the magnetic field magnitudes of electromagnetic coils a1, a3, and a5 is 1:3:5, and the settings of the electromagnetic coils of phase b and phase c are the same as the settings of the electromagnetic coil of phase a. Then at a certain point in time (instant), the magnitude and direction of the synthetic magnetic field waveform on the wound unit ① is the magnitude and direction of the magnetic field generated by the magnitude and direction of the current of the electromagnetic coil b1 at that point in time, superimposed on the magnitude and direction of the magnetic field generated by the magnitude and direction of the current of the electromagnetic coil c5 at that point in time, and then superimposed on the magnitude and direction of the magnetic field generated by the magnitude and direction of the current of the electromagnetic coil a1 at that point in time. By analogy, we can obtain the magnitude and direction of the magnetic field waveforms of all the wound units at that point in time. Therefore, by changing each set of electromagnetic coils of different types (i.e. different number of turns, number of layers, wire diameter, width, thickness, material) on each wound unit, the inductance value (or impedance value) of each set of electromagnetic coils is changed, and the synthetic magnetic field waveform or voltage waveform is changed to achieve the desired waveform effect.
綜上所述,本發明之創新的馬達、發電機或電磁輸送帶之定子或轉子的繞組結構,透過將複數組不同電流相位之電磁線圈繞設在同一被繞線單元的外表面上,使該被繞線單元兼具有集中式繞組結構與分佈式繞組結構的優點,並可有效的解決傳統分佈式繞組結構效率低下及不易設計出理想的合成磁場波形或電壓波形的問題。再者,本發明無論在任一實施例中,皆可透過改變每組電磁線圈的線徑、寬度、厚度、材質、匝數及繞設的層數以在馬達、發電機或電磁輸送帶的每個被繞線單元上改變各組電磁線圈的電感值(或稱阻抗值),並改變合成磁場波形或電壓波形,達到設計所需波形之功效,如此即可達到提升電磁轉換效率、節省製造成本、節省電力及綠色環保之功效,為本案之組成。In summary, the innovative winding structure of the stator or rotor of the motor, generator or electromagnetic conveyor of the present invention, by winding a plurality of sets of electromagnetic coils with different current phases on the outer surface of the same winding unit, enables the winding unit to have the advantages of both the centralized winding structure and the distributed winding structure, and can effectively solve the problems of low efficiency and difficulty in designing an ideal synthetic magnetic field waveform or voltage waveform of the traditional distributed winding structure. Furthermore, in any embodiment of the present invention, the inductance value (or impedance value) of each set of electromagnetic coils can be changed on each wound unit of a motor, a generator or an electromagnetic conveyor belt by changing the wire diameter, width, thickness, material, number of turns and number of winding layers of each set of electromagnetic coils, and the synthetic magnetic field waveform or voltage waveform can be changed to achieve the effect of the waveform required by the design, thereby achieving the effects of improving electromagnetic conversion efficiency, saving manufacturing costs, saving electricity and green environmental protection, which is the composition of the present case.
前述之實施例或圖式並非限定本發明之態樣或使用方式,任何所屬技術領域中具有通常知識者之適當變化或修飾,皆應視為不脫離本發明之專利範疇。The aforementioned embodiments or drawings do not limit the aspects or usage of the present invention. Any appropriate changes or modifications by a person having ordinary knowledge in the technical field should be deemed to be within the patent scope of the present invention.
1:被繞線單元1: Wound unit
10:支架10: Bracket
2:複數組電磁線圈2: Multiple electromagnetic coils
2A:電磁線圈2A: Electromagnetic coil
2B:電磁線圈2B: Electromagnetic coil
2C:電磁線圈2C: Electromagnetic coil
2D:電磁線圈2D: Electromagnetic coil
2E:電磁線圈2E: Electromagnetic coil
2F:電磁線圈2F: Electromagnetic coil
2G:電磁線圈2G: Electromagnetic coil
2H:電磁線圈2H: Electromagnetic coil
2I:電磁線圈2I: Electromagnetic coil
2J:電磁線圈2J: Electromagnetic coil
2K:電磁線圈2K: Electromagnetic coil
2L:電磁線圈2L: Electromagnetic coil
20:絕緣單元20: Insulation unit
圖1是本發明之第一實施例之部分立體示意圖。 圖2是圖1之部分剖視圖。 圖3是本發明之每組電磁線圈設置不同層數之運用例。 圖4是本發明之每組電磁線圈設置不同線徑之運用例。 圖5是本發明之第二實施例之部分立體示意圖。 圖6是圖5之部分剖視圖。 圖7是本發明之複數組電磁線圈使用非圓線之運用例。 圖8是本發明之第二實施例之另一運用例。 圖9是本發明之第三實施例之部分剖視示意圖 圖10是本發明應用於具有彎曲式鐵心之定子之第一實施例。 圖11是本發明應用於具有彎曲式鐵心之定子之第二實施例。 圖12是本發明應用於具有彎曲式鐵心之定子之第三實施例。 FIG. 1 is a partial three-dimensional schematic diagram of the first embodiment of the present invention. FIG. 2 is a partial cross-sectional view of FIG. 1. FIG. 3 is an operation example of the present invention in which each set of electromagnetic coils is provided with different layers. FIG. 4 is an operation example of the present invention in which each set of electromagnetic coils is provided with different wire diameters. FIG. 5 is a partial three-dimensional schematic diagram of the second embodiment of the present invention. FIG. 6 is a partial cross-sectional view of FIG. 5. FIG. 7 is an operation example of the present invention in which a plurality of sets of electromagnetic coils use non-circular wires. FIG. 8 is another operation example of the second embodiment of the present invention. FIG. 9 is a partial cross-sectional schematic diagram of the third embodiment of the present invention. FIG. 10 is a first embodiment of the present invention applied to a stator having a bent iron core. FIG. 11 is a second embodiment of the present invention applied to a stator having a bent iron core. FIG12 is a third embodiment of the present invention applied to a stator having a bent core.
1:被繞線單元 1: Wound unit
2:複數組電磁線圈 2: Multiple sets of electromagnetic coils
2A:電磁線圈 2A: Electromagnetic coil
2B:電磁線圈 2B: Electromagnetic coil
2C:電磁線圈 2C: Electromagnetic coil
20:絕緣單元 20: Insulation unit
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Citations (5)
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CN1495989A (en) * | 2002-09-24 | 2004-05-12 | 三星光州电子株式会社 | Stator windng method of induction motor for compressor |
TW200625760A (en) * | 2004-07-20 | 2006-07-16 | Wavecrest Lab Llc | Motor stator having transposed winding layers |
US20140015352A1 (en) * | 2012-07-13 | 2014-01-16 | Lcdrives Corp. | High efficiency permanent magnet machine with concentrated winding and double coils |
TW201448422A (en) * | 2013-06-11 | 2014-12-16 | Teco Elec & Machinery Co Ltd | A motor wire-winding structure and method thereof |
CN117581450A (en) * | 2021-04-27 | 2024-02-20 | 瓦奥尼克技术有限责任公司 | Coil module for an electric machine |
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Publication number | Priority date | Publication date | Assignee | Title |
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CN1495989A (en) * | 2002-09-24 | 2004-05-12 | 三星光州电子株式会社 | Stator windng method of induction motor for compressor |
TW200625760A (en) * | 2004-07-20 | 2006-07-16 | Wavecrest Lab Llc | Motor stator having transposed winding layers |
US20140015352A1 (en) * | 2012-07-13 | 2014-01-16 | Lcdrives Corp. | High efficiency permanent magnet machine with concentrated winding and double coils |
TW201448422A (en) * | 2013-06-11 | 2014-12-16 | Teco Elec & Machinery Co Ltd | A motor wire-winding structure and method thereof |
CN117581450A (en) * | 2021-04-27 | 2024-02-20 | 瓦奥尼克技术有限责任公司 | Coil module for an electric machine |
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