RU-2861415-C1 - METHOD FOR MANUFACTURING WINDING OF HOLLOW CYLINDRICAL SLOTLESS ARMATURE OF ELECTRIC MACHINE

Abstract

FIELD: electrical engineering. SUBSTANCE: invention can be used in rotors of direct and alternating current motors. A method for manufacturing the winding of a hollow cylindrical armature of an electric machine consists in manufacturing the winding in the form of a single flexible printed circuit board with double-sided metallisation with a contour in the form of arrow-shaped tracks, manufactured by an electrochemical method and interconnected by through-hole metallisation. After forming the tracks, both sides of the board are coated with a dielectric varnish, then the board is spirally rolled into a cylinder on a mandrel, forming four winding layers. The contacts of each layer are soldered together, forming the winding, and the leads are soldered to the conductors of the winding holder coming from the commutator, banded with fluoroplastic film, fixed by pouring a two-component material based on an epoxy resin and a hardener. EFFECT: increasing accuracy and reducing labour intensity of manufacturing the winding of slotless electric motors. 1 cl, 2 dwg

Inventors

• SOLDATOV ALEKSANDR VIKTOROVICH
• Tretiakov Aleksandr Vladimirovich
• Afanasev Sergei Nikolaevich

Dates

Publication Date

20260505

Application Date

20250919

Claims (1)

1. A method for manufacturing a winding for a hollow cylindrical anchor of an electric machine, which consists of manufacturing a winding, placing it on a mandrel and fastening the layers together, characterized in that the winding is manufactured in the form of a single flexible printed circuit board with double-sided metallization with a contour in the form of arrow-shaped tracks manufactured by an electrochemical method and connected to each other by the method of metallization of through holes, after the formation of the tracks, both sides of the board are covered with a dielectric varnish, then the board is twisted in a spiral into a cylinder on a mandrel, forming four layers of winding, the contacts of each of the layers are soldered together, forming a winding, the terminals of which are soldered to the conductors of the winding holder coming from the collector, bandaged with a fluoroplastic film, fixed by pouring a two-component material based on epoxy resin and a hardener.

Description

The present invention relates to the field of electrical engineering, in particular to low- and medium-power electric motors having a winding with an air or smooth core, and can be used in rotors of DC and AC motors. The following method for manufacturing a slotless rotor is known: – a method for manufacturing a winding for a hollow cylindrical anchor of an electric machine involves producing a printed or flat stamped blank of each winding layer, laying the winding layers on a mandrel, fastening the layers together, and connecting the transitions between the layers. In order to expand the technological capabilities by producing windings with three or more layers, the transitions between the inner layers are connected and the layers are pre-fastened before laying the winding layers on the mandrel [SU 1300600 F1, H02 K 15/06 dated 30.03.1987]. The disadvantages of this method are that the armature requires several separate layers to be fabricated, which are then joined into a single circuit. The winding is produced by sequentially layering the conductor and dielectric substrate. This reduces manufacturing accuracy and increases labor intensity. The aim of the invention is to increase the accuracy and reduce the labor intensity of manufacturing the winding of slotless electric motors in order to achieve the required electrical parameters of the winding and its sections based on a mathematical model of the electric motor. In order to achieve the stated objective, a method for manufacturing a winding for a hollow cylindrical anchor of an electric machine is proposed, which consists of manufacturing the winding, placing it on a mandrel and fastening the layers together, in which the winding is made in the form of a single flexible printed circuit board with double-sided metallization with a contour in the form of arrow-shaped tracks manufactured by an electrochemical method and connected to each other by the method of metallization of through holes, after forming the tracks, both sides of the board are covered with a dielectric varnish, then the board is twisted in a spiral into a cylinder on a mandrel, forming four layers of the winding, the contacts of each of the layers are soldered together, forming a winding, the terminals of which are soldered to the conductors of the winding holder coming from the collector, bandaged with a fluoroplastic film, fixed by filling with a two-component material based on epoxy resin and a hardener. The essence of the invention is explained by the drawings: Fig. 1 – Two sides of a flexible printed circuit board. Fig. 2 – Hollow anchor of a commutator motor, where 1 is the winding, 2 is the winding holder, 3 is the commutator, 4 is the shaft. The manufacture of the winding of a hollow cylindrical anchor is carried out as follows. The winding is manufactured using a flexible printed circuit board (PCB) with arrow-shaped tracks. The board is a dielectric substrate with double-sided metallization. A layer of the required thickness is formed using a galvanic method. The winding contour is formed using an electrochemical method. The tracks on both sides are connected to each other using a through-hole metallization method. After the tracks are formed, both sides of the board are coated with a dielectric varnish. The board is then spirally twisted into a cylinder on a special mandrel, thus forming the required number of layers. The outer cylindrical surface is bandaged with fluoroplastic film. After twisting, the terminal contacts of each layer are soldered together, thus forming winding 1. Winding 1 is soldered to the conductors of winding holder 2, leading from commutator 3, and filled with a two-component material based on epoxy resin and a hardener. This produces a hollow anchor.