Patent ID: 12224636

In the drawings:1—coil slot;2—fan hole;3—fly wire slot;4—binding wire hole;5—fastening hole;6—back serial wire joint hole;7—jumper wire joint hole;8—serial wire joint hole;9—back jumper wire joint hole;10—jumper wire slot;11—fastening ring;12—stator disc;13—phase wire inlet end;14—fly wire;15—phase wire outlet end;16—upper-layer single-layer coil;17—lower-layer single-layer coil;18—jumper wire;19—serial wire;20—coil unit;21—single coil;22—single-layer coil;23—wire end code;24—phase inlet wire end code;25—upper-layer single coil;26—lower-layer single coil;27—coil wire;28—phase outlet wire end code;31—auxiliary wire slot;32—main wire slot;33—connecting wire joint hole; and34—auxiliary coil.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention is further described below in combination with the drawings and embodiments: as shown inFIG.1, a stator of a disc-type motor comprises a disc-shaped stator disc12and coil units20fixed in the stator disc; and the stator disc12is fixed on an outer frame by fastening screws. For the disc-type motor, rotors generating magnetic fields are arranged at one side or two sides of the stator disc; the shorter the distance from the stator to the rotors is, the higher the obtained magnetic field intensity is; and the magnetic field intensity is inversely proportional to the square of the interval. Therefore, particularly, for a motor that needs to obtain high output efficiency or needs to have small weight and small volume, the interval of the rotors at the two sides needs to be as small as possible.

The stator disc12is in a flat plat shape and is made of a non-magnetic insulating material; the thickness of the stator disc12is related to the thickness of the coil units; and the thickness is enough for forming channels in the radial outer sides of coil slots1or burying the channels. Theoretically, the greater radial space of the stator disc cannot hinder the running of the motor and the utilization of the magnetic fields.

A space is left at an inner ring of the stator disc12for a motor fan rotating with the rotors; a circle of ring-shaped coil slots1surrounding the center of a circle are formed in the radial outer sides; and the coil slots1are used for fixing and embedding coils.FIGS.2,3and8-13are two side structures of stator discs in four embodiments.

According to different requirements, a main winding on the stator disc12can be provided with one phase of winding or multiple phases of windings; and the multiple phases of windings can provide multi-phase loads, which is beneficial to the balance of current distribution and the reduction of the pulsating torque. An auxiliary wire slot31can also be arranged between main wire slots32of the main winding, which provides output voltage or output power different from the main winding, so as to meet the requirements of detection or control of the motor.

For the main winding, a one-phase coil unit20is fixedly filled in each coil slot1, and one coil unit20is formed by axially overlapping an even number of single coils21; on one stator disc, the coil unit is a basic electric energy generation unit, and the output voltage of one winding is integer multiples of the voltage generated by coil units connected with one another in series. Auxiliary coil units different from the coil units of the main winding can also be arranged as required;FIGS.9and10are a stator disc with the auxiliary wire slots31; and each auxiliary wire slot31is internally provided the auxiliary coil unit.

One coil slot1can also be internally provided with a plurality of coil units20, and the plurality of coil units20in one coil slot1respectively belong to different phases of windings.

Under the situation that a single coil unit20is arranged in one coil slot1, as shown in an embodiment 1 inFIGS.2and3, in the multiple phases of windings, jumper wire slots10, fly wire slots3, serial wire joint holes8and jumper wire joint holes7are formed in the stator disc12at the radial outer sides of the coil slots1, and all the slots and the holes can be circumferentially and uniformly distributed at equal radius in the stator disc respectively, or can be distributed in the regions outside the radial direction of the coil slots1; the effect of the stator disc can be realized flexibly, for example, after connecting wires connected with the coils are led out through the wire slots or pre-buried leading wires, the setting of the output current and the output voltage is realized through series-parallel connection of the coils; and installation positions of detection elements can also be set in connecting regions, and running parameters are detected by utilizing magnetic fields of the rotors.

Most of stator discs are provided with the jumper wire slots10; the two ends of each jumper wire slot10are communicated with the adjacent coil slots1, and can be formed at one side or two sides of the stator disc; the multiple phases of windings are provided with the fly wire slots3; one end of each fly wire slot3is communicated with the coil slot1; the fly wire slots3may be formed in one side or two sides of the stator disc as required, or penetrate through the disc surface of the stator disc; the two ends of each jumper wire slot are used for connecting the coils in the coil slots in the same side in series; a jumper wire18is embedded into the jumper wire slot and refers to a connecting wire of single coils in the adjacent coil slots1; and a fly wire14is embedded into each fly wire slot and refers to a connecting wire of single coils in more than one coil slot1. A serial wire19is a connecting wire between different single coils in the same coil slot1; and the fly wire may be used for connecting the coils that are not adjacent in the same side in series, or may be used for connecting the coils at the different sides in series. The serial wire joint holes8and the jumper wire joint holes7are respectively communicated with the coil slots1through grooves. The jumper wires and the fly wires may be respectively pre-buried into the jumper wire slots10and the fly wire slots3, and the connecting wire is welded at the junction of the fly wire and a coil wire. For the stator disc with auxiliary windings, the auxiliary wire slots31are also formed; the auxiliary wire slots and the coil slots of the main winding are commonly arranged into a ring shape, and the auxiliary wire slot is formed between the coil slots; and auxiliary coil windings are independent and are not connected with any main winding in series.FIGS.9and10are a structure of the stator disc with the auxiliary wire slots31.

By using the wire slots of the stator disc, the coil wires can be connected stably in a manner of not protruding out of the disc surface, and the insulation between different conducting wires can be directly realized without insulating layers of the conducting wires. In addition, the connecting wires can be intuitively observed from the disc surface, so as to identify different types of stator discs. Meanwhile, the flexible connection setting can be performed for the coil units by utilizing the coil slots, a lot of single-phase output can be set as required, or can be set according to different voltage and current requirements. Because the coil units are modularized, replacement and rapid assembly are facilitated.

With reference to embodiments inFIGS.4and5, a coil unit20of the main winding is one single coil21formed by winding one coil wire27along the same direction without branches or iron cores; one single coil21is formed by axially overlapping two layers of single-layer coils22; the cross section of one single-layer coil22is a rectangle or a rounded rectangle; and relative to the axial direction of the stator disc, the thickness of one single-layer coil22is the thickness of the single coil wire27, and the width direction of the coil wire27is the axial direction of the stator disc. The single-layer coil22is formed by spirally winding in a disc shape in a plane, two wire ends of one single coil21respectively belong to an upper-layer single-layer coil16and a lower-layer single-layer coil17; and the two wire ends are located at the outer side of the spiral coil; and the upper-layer single-layer coil is wound from an inner ring to an outer ring, directly jumps to an inner ring of the lower-layer single-layer coil and is wound out in a disc shape.

One phase of winding in the multiple phases of windings is formed by connecting a plurality of single coils21by the serial wire19, the jumper wire18and the fly wire14in series; each phase of winding is in centrosymmetric distribution relative to the center of the circle of the stator disc on the stator disc; or auxiliary coils or coil slots of non-main windings may also be inserted into the arrangement of the coil slots in the disc surface of the stator disc, which are not in centrosymmetric distribution.

As shown inFIGS.4and5, without regard to the auxiliary coil windings, all the coil units are arrangement structures of the multiple phases of windings of the main windings; in addition, under the situation that only one coil unit is arranged in one coil slot, the plurality of single coils21in each coil slot1are connected in series into a coil unit20, each phase of winding comprises M coil units20, and M=the total number of the coil slots of the main windings/the phase number; and the M coil units are uniformly divided into N regions, each region comprises P coil units, and M, N and P are natural numbers greater than 1. By takingFIGS.6and7as examples, inFIGS.6and7, a minimum thick line frame represents a coil unit; a digit in each cell represents the serial number of the wire end of the single coil; and in one coil unit, the upper row is the upper-layer single coil, and the lower row is the lower-layer single coil. InFIGS.6and7, solid lines, close-interval dotted lines and sparse-interval dotted lines respectively represent conducting wires of three phases of windings.FIG.7shows twelve coil slots and three phases of windings; each phase of winding comprises four coil units and is divided into two groups; each group comprises two coil units; M, N and P here are respectively4,2and2; and a structure of the stator disc corresponding toFIG.7is shown inFIGS.11and12.FIG.6shows twenty-seven coil slots and three phases of windings; each phase of winding comprises nine coil units and is divided into three groups; each group comprises three coil units; M, N and P here are respectively9,3and3; and a structure of the stator disc corresponding toFIG.6is shown inFIGS.2and3.FIG.8is a schematic diagram of a wire connection manner between the single coils with auxiliary windings, three windings of auxiliary coils D1-L1, D2-L2 and D3-L3 are the auxiliary windings, and electric energy is independently output.

FIGS.13and14show a structure of a stator disc only with one phase of winding on the stator disc; and in such the stator disc, the jumper wires in the jumper wire slots only need to be connected with the coils in each coil slot of the main winding. A winding method of the stator of the disc-type motor mainly comprises the following steps:

1. Respectively Making the Single Coils and the Stator Disc

Due to modularization of the single coils, the single coils can be independently made and can be replaced on the stator disc, so that the single coils can be produced as semi-finished products; and one single coil is integrally formed by the upper-layer single-layer coil and the lower-layer single-layer coil, wherein the coil wire is not discontinuous.

As an embodiment of winding of the single coil, the winding manner of the single coil is simultaneously winding a set circle number in opposite spiral directions in the middle of the coil wire, and then coaxially stacking coils in a double-layer manner, to form two layers of single-layer coils which are screwed in from one wire end and then wound out from the other wire end in the same spiral direction. Finally, an outline formed by winding needs to be embedded into the coil slot1.

The stator disc is a stator base with connecting positions and welding positions being planned and can be formed by a high polymer material through a mould at one step.FIGS.2and3are the embodiment of the stator disc without installing the coils.

After an even number of layers of prefabricated single coils21are overlapped and filled into the coil slot1, the wire ends of the single coils extend out of the preset wire slots, fixing glue is coated between the single coils21and the coil slots1, and the fixing glue is solidified for fixing the single coils;

2. Pulling the Wires

For each single coil, the wire end of the upper-layer single-layer coil16is set as a wire inlet end, the wire end of the lower-layer single-layer coil17is set as a wire outlet end, and connecting slot positions are found for the wire ends of each phase of single coil in the wire pulling process. The single coil is connected by the serial wire, the jumper wire or the fly wire in the region at the radial outer side of the coil as required. The final connection needs welding through a welding hole; and in the step of pulling the wires, the wire ends of the single coil are arranged at the corresponding connecting wire slot positions.

If the same coil slot1is only internally provided with one phase of coil, the single coils are connected with each other by the serial wire necessarily and only have two connection manners, and the current directions of the two connection manners are opposite. The coils on one stator disc need to be integrally planned in advance, the current directions of each phase of coil are consistent, and the current directions need to be made by matching magnetic pole positions. Under the principle, the corresponding positions of the serial wires, the jumper wires and the fly wires are planned.

The wire ends connected with the serial wires are embedded into serial wire grooves and the serial wire joint holes8; the wire ends of the adjacent single coils, which are connected with the jumper wires, are embedded into corresponding jumper wire grooves and the jumper wire joint holes7; and the wire ends connected with the fly wires and phase wires are embedded into the corresponding fly wire slots3. The conducting wires with insulating layers, which serve as the fly wires14, are fixed at the corresponding positions of the periphery of the stator disc12when needed.

FIGS.6and7are respectively an arrangement solution of 27-hole coil slots and an arrangement solution of 12-hole coil slots.

3. Connecting

After the positions of the wire ends of each phase of coil are arranged into the corresponding wire slot, the connected serial wires and/or jumper wires are welded; when the fly wire exists, a wire end of the fly wire is connected with a corresponding fly wire connecting end; and after a welding line is solidified, a joint can be plugged into the serial wire joint hole8or the jumper wire joint hole7, thereby eliminating the connecting wire joints protruding out of the surface of the stator disc after being welded. After a unified tin soldering, the connection of the whole coil wire is completed.