KR-102961627-B1 - Brushless motor manufacturing method for air compressor of hydrogen car applying multi-winding of 2 poles and 6 slot

Abstract

The present invention relates to a method for manufacturing a brushless motor for a hydrogen vehicle air compressor, and The number of motor slots is 12 or more, and Manufactured using distributed winding, the present invention enables high-speed rotation and is efficient due to high torque and low heat generation. It also offers the significant effect of low manufacturing costs resulting from the use of NdFeB magnets and SUS (stainless steel) sleeves. Furthermore, increasing the number of slots leads to significant improvements in efficiency and temperature reduction.

Inventors

• 정진근
• 최원태

Assignees

• 효성전기주식회사

Dates

Publication Date

20260507

Application Date

20221026

Claims (2)

1. A method for manufacturing a brushless motor for a hydrogen vehicle air compressor, wherein the motor has 12 slots, is manufactured with distributed winding, and applies a 2-pole 12-slot multi-winding, wherein the motor has 12 teeth and applies a 2-pole 12-slot multi-winding. The diameter of the stator core of the above motor is 80 to 130 mm, and the length of the stator core (10) is 40 to 80 mm. A sleeve (70) is located inside the stator core (10), and a shaft (50) is located inside the sleeve (70). An N-pole magnet (62) and an S-pole magnet (61) attached to the outer circumference of the shaft (50) are made of NdFeB material, and the sleeve (70) is made of stainless steel. It is a 2-pole, 12-slot, 2-pitch BLDC type based on a 3-phase U, V, and W configuration. The coils for each phase are wound individually with 2 pitches, but the final grounds converge at a single point. The U, V, and W phases are inserted into the core after forming their respective coil sections. For the U phase, one coil section is inserted into the space between segments 2 and 3, and an additional coil section is inserted between segments 5 and 6 to ultimately converge into the U phase and ground. For the V phase, one coil section is inserted into the space between segments 1 and 2, and an additional coil section is inserted between segments 4 and 5 to ultimately converge into the V phase and ground. For the W phase, one coil section is inserted into the space between segments 1 and 6, and additionally A method for manufacturing a brushless motor for a hydrogen vehicle air compressor using a 2-pole, 12-slot multi-winding, characterized by inserting one coil forming section into the space between the 3rd and 4th segments to finally converge into the W phase and ground, and then connecting the final converged ground and 3 phases based on the final output section.
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Description

Brushless motor manufacturing method for air compressor of hydrogen car applying multi-winding of 2 poles and 6 slots The present invention relates to a method for manufacturing a brushless motor for a hydrogen vehicle air compressor, and more specifically, it has the significant effect of enabling high-speed rotation, having high torque while generating little heat, being efficient, and having a low manufacturing cost due to the use of NdFeB magnets and SUS sleeves (stainless steel). In addition, it relates to a method for manufacturing a brushless motor for a hydrogen vehicle air compressor that increases efficiency and reduces temperature by increasing the number of slots. Generally, brushless motors are widely used in air conditioners, and as an example of prior art, Publication No. 10-2008-0075396 describes a brushless DC motor comprising: a rotor having a permanent magnet; A stator having a plurality of phase coils that form an electric field to generate torque through interaction with a magnetic field generated from the above-mentioned permanent magnet; A brushless DC motor is disclosed, characterized by including a load protection unit disposed within the stator and configured to electrically connect and disconnect the plurality of phase coils according to a temperature change. In addition, Patent No. 10-0695581 discloses a motor driving device for driving a brushless motor, comprising an inverter circuit that converts the output voltage of a voltage source into a driving voltage and outputs it to the brushless motor, a rotor position estimation unit that estimates the rotor position of the brushless motor, and an inverter control unit that controls the inverter circuit so that the brushless motor is driven by a current based on the estimated rotor position, wherein the inverter control unit controls the actual rotational speed of the brushless motor and repeatedly adjusts the phase difference between the estimated rotor position and the current supplied to the brushless motor so that the actual rotational speed of the brushless motor matches the commanded rotational speed, which is the target value, according to the change in the rotational speed of the brushless motor caused by the previous adjustment of the phase difference. However, the conventional concentrated winding method shown in Fig. 1 (a method of winding or inserting the winding onto a single tooth) for a hydrogen vehicle air compressor had the disadvantage that it was difficult to drive the motor efficiently due to severe heat generation during high-speed rotation. In addition, the general brushless motor based on the distributed winding method shown in Fig. 2 (a method of winding or inserting the winding across at least two teeth) had the problem that it could not be used for application to a hydrogen vehicle air compressor because the optimal design regarding rotational speed, torque, size specifications, number of teeth, and number of windings was not achieved. Conventionally, in the case of 6 slots As a manufacturing method, it was manufactured through the process of split core → concentrated winding → 6-slot core array → welding. However, since the motor is assembled by winding coils onto the stator core using a concentrated winding method, there is a high possibility of quality issues arising because the coil temperature exceeds design requirements when operating at the air compressor's maximum output. Although additional cooling was provided by increasing the number of cooling air holes, this resulted in reduced efficiency and unsatisfactory design requirements. Figure 1 is an explanatory diagram of a conventional concentrated winding motor. Figure 2 is a photograph of a conventional concentrated winding motor. Figure 3 is an explanatory diagram of a conventional distributed winding motor. Figure 4 is a photograph of a conventional distributed winding motor. FIG. 5 is a manufacturing process diagram of a brushless motor for a hydrogen vehicle air compressor according to the present invention. FIG. 6 is a magnetic coupling diagram of a brushless motor for a hydrogen vehicle air compressor according to the present invention. Figure 7 is a graph of the temperature measurement of the distribution zone of the brushless motor for a hydrogen vehicle air compressor according to the present invention. FIG. 8 is a comparative diagram of the magnet materials of the brushless motor for a hydrogen vehicle air compressor according to the present invention. FIG. 9 is a comparative diagram of the sleeve material of the brushless motor for a hydrogen vehicle air compressor according to the present invention. Fig. 10 is a photograph of a conventional motor with 6 slots. FIG. 11 is a photograph of a motor with 12 slots according to the present invention. FIG. 11a is a photograph of a motor with 12 slots marked with the TIS number of the present invention. FIG. 11b is a method of inserting into a core after forming the coil forming portions of the