Electric vehicle hub motor stator and manufacturing method thereof

Abstract

The invention discloses an electric vehicle hub motor stator comprising an iron core and a bracket. The bracket is used for fixing the iron core. The iron core comprises a yoke part, tooth parts and wire embedding slots. The wire embedding slot is formed between two adjacent tooth parts. The electric vehicle hub motor stator is characterized in that the stator iron core is made by the winding process, the outer diameter size of the iron core is 140-160 mm, and the inner diameter size of the iron core is 100-120 mm. According to the electric vehicle hub motor stator, the consumption material isless and the manufacturing efficiency is higher than those of the same level product under the condition that the product performance reaches the standard through reasonable design of the size of thestator inner diameter and outer diameter and the size of the yoke. Compared with the stator iron core with the same outer diameter, the stator iron core has larger inner diameter, forming and installing of the bracket are facilitated, the iron core material is saved and the stability of the bracket and the convenience of installation and maintenance are enhanced. The original single punching or double riveting process is replaced by the winding and self-buckling process of the stator core so as to reduce the material loss and improve the production efficiency.

Description

technical field [0001] The invention relates to the field of electric vehicle motors, in particular to a stator of an electric wheel hub motor and a manufacturing method thereof. Background technique [0002] As a means of transportation, electric vehicles have the characteristics of environmental protection, energy saving, and convenience, and are favored by people all over the country. Due to the differences in terrain between the north and the south and the road conditions in urban and rural areas, the consumption propensity for electric vehicles varies in different regions. In the southern region, electric motorcycle models are often used, while in the northern region, simple models are mainly used. The size of the hub motor basically determines the size of the stator core. The large hub motor has the characteristics of large power and torque, and has a relative climbing effect, which is suitable for mountain residents to travel; but in some areas, especially in norther...

AI Technical Summary

Problems solved by technology

[0004] In the prior art, the outer diameter of the stator core corresponding to the small-sized hub motor is relatively small, generally 140-160 mm, resulting in a relatively small internal diameter of the stator core, generally within 95 mm

The inner diameter of the stator core is too small, which brings a series of troubles and shortcomings

[0005] First of all, the inner diameter of the stator core determines the outer diameter of the bracket. A bracket with a small outer diameter is difficult to form, has low strength, and has potential safety hazards in use.

[0006] Second, the installation space of the bracket is small, which increases the difficulty of motor installation, and brings inconvenience to placing rivets and welding operations during installation, which not only reduces production efficiency, but also affects product quality

[0007] In addition, in the existing technology, the small-sized stator core is processed by single punching or stacking riveting process. The utilization rate of raw materials in this process is low. If the recycling of corners is not considered, the utilization rate is only about 30%, and the consumables are serious. low production efficiency

The single-piece process has low production efficiency and many consumables; the stacking riveting process has a large blanking area and is prone to noise pollution and many consumables

[0008] Furthermore, due to slot-specific dimensional constraints, it cannot be achieved with a winding process

The progressive die in the winding process is the most core die, and the corresponding step distance is required. The step distance={(groove bottom-stator slice inner diameter)*0.5+stator slice inner diameter}*π / number of slots, and the step distance is then used Calculate the notch size. If most single-punch grooves are designed according to the winding process, the notch size will not meet expectations. If the notch is too large, the motor noise will increase, and if the notch is too small, it will be difficult to wind.

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