The winding method for the stator winding of a quadruple-axis aircraft model motor has a crucial impact on efficiency and stability. The key lies in balancing performance targets by optimizing coil distribution and electromagnetic field characteristics. Among various winding methods, double-layer stacked winding, due to its unique structural advantages, is a key choice for improving efficiency and stability. This winding method divides the coils into two layers, one above the other, embedded in the stator slots. Each layer's coil sides belong to different coil groups. This layered layout significantly reduces electromagnetic interference between coils. Compared to single-layer winding, double-layer stacked winding allows for more flexible coil pitch adjustment, resulting in a short-pitch winding structure that reduces end length by approximately 30%, reducing copper loss and improving energy conversion efficiency. Furthermore, the short-pitch design reduces high-order harmonics in the air gap flux density, making the magnetomotive force waveform closer to a sine wave, effectively suppressing vibration and noise, and enhancing operational stability.
Distributed winding achieves magnetic field balance by evenly distributing coil groups, further enhancing stability. This design, with multiple coils embedded and wired in a specific pattern at each pole, avoids the localized overheating associated with concentrated magnetic fields in centralized winding. Taking concentric winding as an example, it utilizes rectangular coils of varying sizes, nested layer by layer around the same center, forming a zigzag structure. This ensures magnetic field uniformity while distributing electromagnetic forces through the layered layout, reducing vibration amplitude. This design is particularly important in high-speed operation, effectively preventing coil displacement caused by centrifugal force and ensuring long-term operational reliability.
The combined application of double-layer winding and distributed winding demonstrates significant advantages in improving efficiency. The double-layer structure increases electromagnetic energy conversion efficiency per unit volume by increasing coil density, while the distributed layout reduces iron loss by optimizing magnetic field distribution. The synergistic effect of these two methods reduces copper and iron losses by approximately 15% for the quadruple-axis aircraft model motor at the same power output. This reduction in energy loss directly translates into improved range, especially in high-frequency response scenarios. Furthermore, this combined design enhances the quadruple-axis aircraft model motor's adaptability to load changes, enabling rapid adjustment of magnetic field strength during dynamic flight to maintain stable output torque.
Refined control of the winding process is critical to ensuring both efficiency and stability. Automated winding equipment enables precise control of parameters such as coil pitch and tension, eliminating parameter deviations caused by manual winding. For example, a bus-based PLC motion controller combined with a professional servo system ensures winding trajectory errors of less than 0.1mm, increasing coil density by 50%, thereby reducing electromagnetic leakage and energy loss. Furthermore, advanced tension control technology monitors enameled wire tension in real time, preventing coil deformation caused by tension fluctuations and ensuring consistent winding quality.
Material selection and pretreatment processes have a fundamental impact on winding results. Selecting enameled wire with high conductivity and strength reduces resistance loss and improves coil deformation resistance. Wire pretreatment processes such as degreasing and cleaning ensure a smooth winding process and reduce the risk of wire breakage due to friction. In terms of mold design, high-precision positioning fixtures prevent coil misalignment caused by positioning deviations during winding, ensuring precise alignment of each coil layer and maintaining a uniform magnetic field distribution.
Maintenance and real-time monitoring are crucial measures to ensure long-term stability. Regularly inspecting the winding insulation and cleaning dust accumulation can prevent short-circuit failures caused by insulation aging or contamination. The operating parameter monitoring system provides real-time feedback on key indicators such as current, voltage, and temperature, providing data support for preventive maintenance. For example, monitoring winding temperature changes can proactively identify potential local overheating risks, allowing for timely load adjustments or optimized heat dissipation design to prevent performance degradation caused by heat accumulation.
The quadruple-axis aircraft model motor's stator winding utilizes a combination of double-layer stacking and distributed winding, coupled with refined process control, high-quality material selection, and a comprehensive maintenance system, significantly improving efficiency and stability. This design not only meets the quadruple-axis aircraft model motor's requirements for high power density and fast response, but also optimizes electromagnetic field distribution and reduces energy loss, providing technical support for reliable operation in complex flight scenarios.
