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CN-122001125-A - Enhanced coreless stator and coreless disc motor

CN122001125ACN 122001125 ACN122001125 ACN 122001125ACN-122001125-A

Abstract

The invention discloses an enhanced coreless stator and a coreless disc motor, which comprise a substrate, wherein a stator winding is arranged on the substrate, the stator winding comprises an effective conductor section for cutting axial magnetic flux, the effective conductor section is sheet-shaped, and the main plane of the effective conductor section is not parallel to the plate surface of the substrate. According to the invention, through changing the relative position relation between the effective conductor sections and the substrate, the single effective conductor section has the traditional current flow section and simultaneously has the resistance capability to larger magnetic acting force, and the coreless stator has larger structural strength and more stable operation. Meanwhile, the axial projection of the flaky effective conductor segments on the substrate is small in occupied area, and the stator windings can be distributed more on the substrate with the same area. The invention synchronously improves the strength of the single-turn structure and the number of turns in unit area, obviously enhances the strength of the whole structure of the stator, and improves the energy density of the motor at the same time, thereby realizing higher power output.

Inventors

  • ZHANG XIONGFENG

Assignees

  • 维尔纳集电电子科技(福建)有限公司

Dates

Publication Date
20260508
Application Date
20260129

Claims (15)

  1. 1. The enhanced coreless stator comprises a substrate, wherein the substrate comprises more than one single plate stacked, a stator winding is arranged on the substrate and comprises an effective conductor section for cutting axial magnetic flux, and the enhanced coreless stator is characterized in that the effective conductor section is sheet-shaped, and the main plane of the effective conductor section is non-parallel with the plate surface of the substrate.
  2. 2. The enhanced coreless stator of claim 1 wherein the major plane of the active conductor segment is perpendicular to the face of the substrate.
  3. 3. The reinforced coreless stator of claim 1, wherein the angle α between the major plane of the active conductor segment and the substrate surface satisfies the relationship 45 < α <90 °, and the projections of any two adjacent active conductor segments onto the substrate overlap.
  4. 4. The reinforced coreless stator of claim 1, wherein the substrate has a slot formed therein, the slot being in one-to-one correspondence with the active conductor segments, the active conductor segments being secured within the slot.
  5. 5. The reinforced coreless stator of claim 4, wherein the slot extends in a direction perpendicular to the major surface of the base plate.
  6. 6. The reinforced coreless stator of claim 4, wherein the base plate is coaxially provided with an annular through hole, the strip-shaped grooves are positioned on the annular through hole, each strip-shaped groove is divided into a first end part and a second end part by the annular through hole, and the first end part and the second end part are respectively positioned on the base plate at two sides of the annular through hole.
  7. 7. The reinforced coreless stator of claim 1, wherein the base plate is provided with a mounting portion fixedly connected with the motor casing, a plurality of insulating heat dissipation ribs are mounted on the surface of the base plate, one end of each insulating heat dissipation rib is connected with the effective conductor section, and the other end of each insulating heat dissipation rib extends to the mounting portion of the base plate.
  8. 8. The reinforced coreless stator of claim 7, wherein the mounting portion is located at an outer peripheral edge of the base plate or an inner peripheral edge of the base plate.
  9. 9. The reinforced coreless stator of claim 7, wherein the mounting portion of the base plate is coaxially provided with a reinforcing ring, and the end portion of the insulating heat dissipating rib extending to the mounting portion is connected with the reinforcing ring.
  10. 10. The reinforced coreless stator of claim 7, wherein the insulating ribs are disposed on both sides of the base plate.
  11. 11. The reinforced coreless stator of claim 7, wherein the insulating ribs are distributed on both end sides of each effective conductor segment, and both ends of each effective conductor segment are connected with the insulating ribs on the corresponding end sides in a one-to-one correspondence.
  12. 12. The reinforced coreless stator of claim 7, wherein the outer peripheral edge of the base plate and the inner peripheral edge of the base plate are provided with mounting portions, insulating heat dissipation ribs are distributed on two end sides of each effective conductor section in a one-to-one correspondence manner, one end of each insulating heat dissipation rib is connected with the end portion, close to the effective conductor section, of each effective conductor section, and the other end of each insulating heat dissipation rib extends to the mounting portion, close to the mounting portion, of each effective conductor section and is connected with the reinforcing ring.
  13. 13. The reinforced coreless stator of claim 7, wherein the substrate is a circular ring structure, the effective conductor segments are strip-shaped sheets, the insulating heat dissipation ribs are strip-shaped, all the effective conductor segments on the substrate are distributed in a scattering manner, and the length direction of the insulating heat dissipation ribs and the length direction of the effective conductor segments are positioned on the same straight line.
  14. 14. The reinforced coreless stator of claim 1, wherein the single plate is a polymeric composite plate.
  15. 15. The reinforced coreless disc motor is characterized by comprising the reinforced coreless stator, the rotor, the rotating shaft and the motor shell according to any one of claims 1-14, wherein the rotating shaft is rotatably arranged on the motor shell, the reinforced coreless stator and the rotor are positioned in the motor shell, the number of the rotors is two, the two rotors are respectively positioned at two sides of the reinforced coreless stator, the rotor is fixedly arranged on the rotating shaft, the reinforced coreless stator is rotatably arranged on the rotating shaft, and the reinforced coreless stator is fixedly connected with the motor shell.

Description

Enhanced coreless stator and coreless disc motor Technical Field The invention relates to the technical field of motors, in particular to an enhanced coreless stator and a coreless disc motor. Background The disc type coreless motor has become a core driving component in high-end fields such as aerospace, electric vehicles, wind power generation, robots, numerical control machine tools and the like by virtue of the advantages of small volume, light weight and high torque density and power density. However, the stator structure of the stator is difficult to achieve both light weight and high strength for a long time, the traditional winding coil is directly laid on a disc surface and glued, the wiring consistency is poor, the manual links are many, and large-scale and automatic production cannot be realized, while the recently rising PCB stator can utilize a mature photoetching-etching process to form the winding in a multilayer printed board at one time, the production efficiency is high, the consistency is good, and a new mechanical short board is exposed. The PCB substrate body is made of epoxy resin-glass fiber composite material, has low elastic modulus and weak bending resistance, and the surface copper foil can serve as a conductive circuit and also serve as a local reinforcing layer, but the thickness is usually only 18-35 mu m and is far smaller than the requirement of structural bearing. To reduce the winding resistance, the design is forced to enlarge the copper foil line width, resulting in the copper foil principal plane being perpendicular to the motor axis, the alternating electromagnetic force generated by the axial magnetic flux directly acts on the copper foil surface vertically, the bending rigidity of the copper foil is extremely poor, and plastic deformation is easy to occur. Meanwhile, the effective turns are compressed by the increase of the line width, the turns in unit area are reduced, and the overall reinforcing effect of the copper foil on the substrate is further weakened. As a result, the PCB stator has significant axial warpage and radial vibration during high-speed and high-load operation, distorted air gap magnetic field distribution, a rapid increase in the fatigue cracking risk of the copper foil, a sudden drop in the energy conversion rate of the motor, and difficult realization of high-power and long-life operation. Disclosure of Invention The invention provides an enhanced coreless stator. The technical scheme for achieving the purpose of the invention is that the reinforced coreless stator comprises a substrate, wherein the substrate comprises more than one single plate stacked, a stator winding is arranged on the substrate, the stator winding comprises an effective conductor section for cutting axial magnetic flux, the effective conductor section is sheet-shaped, and the main plane of the effective conductor section is non-parallel to the plate surface of the substrate. Further, the main plane of the effective conductor section is perpendicular to the substrate surface. When the main plane of the effective conductor section is perpendicular to the plane of the substrate, the plane of the effective conductor section is parallel to the axial magnetic field force, the axial magnetic field force completely acts on the effective conductor section in the direction parallel to the plane of the effective conductor section, and as the bending resistance of the effective conductor section in the direction parallel to the plane of the effective conductor section is stronger, the structural strength is higher, the deformation resistance of the effective conductor section is stronger, and after the plane of the effective conductor section is perpendicular to the plane of the substrate, the occupied area of each effective conductor section on the substrate is smaller, the distributable density of the effective conductor section on the substrate is higher, and the distributable quantity of the effective conductor sections on the substrate with the same area is more. The number of the effective conductor sections on the substrate is more, the strengthening effect is more obvious, and the structural strength of the substrate is stronger and the energy density is also higher. Further, the included angle alpha between the main plane of the effective conductor section and the substrate surface satisfies the following relation that 45 degrees < alpha <90 degrees, and the projection parts of any two adjacent effective conductor sections on the substrate are overlapped. After the effective conductor segments are obliquely arranged relative to the substrate, the resistance of a single effective conductor segment to axial magnetic field force is far greater than that of the effective conductor segments arranged in parallel relative to the substrate at an angle of 45 degrees < alpha <90 degrees, although the resistance of the single effective conductor segment to axial magnetic field force is n