Winding technology is the core barrier of hollow cup motor

 

The hollow cup brushless motor is widely used in various precision equipment because of its small size and light weight. Among them, the most important structure includes stator assembly, hollow cup assembly, sensor assembly, rotor, end cap several bearings and so on. In order to reduce the cogging torque and reduce the starting torque, the stator core adopts the cogging structure, and the three-phase stator winding adopts the winding cup structure. The Hall element sensor is located inside the motor, through the sensor magnetic steel coaxial link with the main magnetic steel rotor, the precise position of the motor. The positioning process depends on the position adjustment of the winding cup and the precise adjustment of the sensor. The winding cup structure, as a key part of the hollow cup brushless motor to reduce the tooth groove torque, its design and manufacture is very important to the motor erformance.

 

Click to view: More about the hollow cup motor slotless features of introduction

 

 

The mechanism design of the winding cup and a number of important factors, such as the uniform distribution of the independent coil in the winding cup, the fixed way of the winding cup and the welding technology of the lead wire, etc., which directly affect the working efficiency and performance of the motor. The winding structure is mainly composed of three phases of symmetrical distribution of winding, winding fixed bracket and lead wire welding plate. The winding of the winding cup will be precisely wound first in the production to ensure the three-phase symmetry of the winding, and then the insulation treatment, and finally the winding cup is fixed on the winding cup fixing frame to ensure the stable operation of the motor.

 

 

The stator hollow cup assembly is composed of a winding cup, a winding cup fixing frame and a sensor assembly, etc. After precision winding, the winding cup is shaped circumferentially to form a three-phase symmetrical winding structure, and is treated with insulation. The fixed winding cup is connected with the sensor assembly through the lead wire, and the middle wire in the three-phase winding is connected through the circuit board. Finally, the lead wire is led from the circuit board together with the sensor lead wire to provide a stable current supply to the motor.

 

 

Straight winding: In this structure, the active conductor part of the component is parallel to the armature axis, which is a concentrated winding. When winding, the enameled wire is wound in a ring on the die according to the number of turns required, and then unfolded and arranged on the core shaft of the armature cup. This winding method has high slot filling rate and thin middle wall, but because of irregular arrangement of enameled wire during winding, it may cause confusion of wire arrangement and larger end size.

 

Inclined winding (honeycomb winding) : This winding form adopts honeycomb winding method, and the armature axis and the effective edge are tilted at a certain Angle when winding. Because of the need to use a special winding mandrel, and the winding process is complex, the oblique winding structure can ensure that the end of the winding size is small. Although the slot filling rate is low, the characteristics of continuous winding make this method suitable for motors with higher precision requirements.

 

Rhomboid form: This structure is wound into a shape coil first, and then the way of wiring. The self-adhesive enamelled wire is wound on the special winding die, and the dimensional accuracy and slot filling rate of the armature cup are improved by shaping the arrangement. The advantage of diamond winding method is high production efficiency, suitable for mass production, and can better control the stability of the winding and motor performance.

 

 

Compared with the ordinary core motor, the hollow cup motor has significant performance advantages, but its manufacturing process is more complex. The core of hollow cup motor production lies in the winding of the coil, which requires the self-adhesive enamelled wire to be closely arranged and eventually form a regular cup-like structure. This process requires extremely high technical and precision requirements, and is an important barrier in the manufacturing process.

 

The main way of winding process

At present, there are three main methods for winding hollow cup motor coils:

1. Manual winding: mainly through manual operation, through the insertion of pins, manual winding and manual wiring and other complex steps to complete the production, this way the cost is lower, but the efficiency and consistency are relatively poor.

 

2. Semi-automated production (winding technology)

Semi-automatic production first of all, the enameled wire is wound to the main axis of the diamond interface in order to reach the required length, and then removed and flattened into a wire plate, and then wound into a cup coil. This method improves efficiency, but it requires some manual intervention.

 

3. Automated production (one-time molding technology)

One-time forming technology through the automatic equipment to complete the regular winding of enameled wire, directly formed cup coil after removal. This method has high degree of automation, fast production efficiency, tight coil arrangement and stable quality, and is the mainstream choice of the current international advanced manufacturers.

 

The core barrier of winding process

The winding process of the hollow cup motor is extremely complex, and the processing difficulty is far more than that of the traditional motor. The entire manufacturing process includes nearly 30 processes, from the early line winding to the bearing, mandrel, support ring installation in the middle, and then to the rear cover installation and circuit board welding in the later period. Among them, coil manufacturing is one of the most important links. Some manufacturers with weak technical strength mainly rely on semi-automatic winding technology, while the international leading manufacturers have already adopted highly automated one-time forming technology. These manufacturers with advanced equipment, to achieve high efficiency production, to ensure coil quality and motor performance to reach a higher level.

 

 

Widely used in many fields

With the rapid development of industrial technology, hollow cup motor shows irreplaceable value in many fields with its unique performance, especially in the following scenarios:

 

Rapid response servo system

In servo systems requiring rapid response, hollow cup motors provide high precision control and flexible adjustment.

 

Stable and durable drive equipment

For drag-drive parts that need to run stably for a long time, hollow cup motors are ideal for their high efficiency and low energy consumption.

 

Aerospace and modeling fields

Hollow cup motors are increasingly used in the aerospace field, from aircraft models to sophisticated aviation equipment, can play a key role.

 

Civil electrical appliances and industrial products

In a variety of household appliances and industrial equipment, hollow cup motor with its miniaturization, high efficiency characteristics become a widely used core components.

 

Future development trend

The performance requirements of hollow cup motor in industrial enterprises continue to improve, which makes its application in servo control, precision equipment, aerospace and high-end civil and industrial fields gradually become the mainstream direction of future development. With the progress of technology and the expansion of market demand, the research and development and application of hollow cup motor will move to a higher level, providing more innovation and possibilities for various industries.

 

 

After more than ten years of development, VSD focuses on micromotor manufacturing and customization, and is committed to providing customers with high-performance, high-reliability motor products and solutions. With the control motor and its drive control system as the core, VSD has steadily expanded its business around the field of full automation and intelligence, and formed a rich product line covering stepper motor, DC brushless motor, AC servo motor and hollow cup motor. It focuses on emerging industries such as service robots, industrial robots, medical equipment, new energy vehicles, intelligent driving vehicles, and solar energy equipment, and promotes technological upgrading and intelligent development in related fields. With its leading technical strength and rich industry experience, VSD provides customers with accurate and reliable motor support to help the innovation and progress of the global industry.

 

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