Straight bar splicing type stator iron core for frameless torque motor

Abstract

The invention discloses a straight bar splicing type stator core for a frameless torque motor, and relates to the field of stator cores, the straight bar splicing type stator core comprises a stator core body, the initial state of the stator core body is a straight bar shape, stator core split bodies are arranged in a straight line, the inner side projection of the stator core body is provided with a stator core tooth part, and the inner side projection of the stator core body is provided with a stator core tooth part. Coils are sequentially wound on the tooth parts of the stator core, and after the coils are wound, the stator core body is subjected to integral circle surrounding welding. According to the straight bar splicing type stator iron core for the frameless torque motor, the stator iron core body adopts a straight bar type design, the split structures of the stator iron core body are arranged in a straight line, and the connection part of each split body is provided with a process hole which is specially used for eliminating internal stress generated in the manufacturing and operation processes, so that the production process is simplified, the production efficiency is improved, and the production cost is reduced. And the uniformity and the stability of the iron core are ensured, the stress concentration is effectively reduced, the production speed and the production efficiency are improved, meanwhile, the manual intervention requirement is reduced, and large-scale manufacturing is facilitated.

Description

Technical Field

[0001] This invention relates to the field of stator core technology, specifically to a straight-bar spliced ​​stator core for a frameless torque motor. Background Technology

[0002] Stator cores are typically made of low-carbon oriented silicon steel sheets stacked together. The windings are arranged through a segmented slot design, and copper and iron losses are reduced through heat treatment and coating. In frameless torque motors, the stator core plays a fundamental role in providing the core magnetic circuit and torque conversion. At the same time, by optimizing the lamination structure and heat dissipation design, efficient and stable motor performance is achieved.

[0003] In the existing technology, the winding method of stator core is relatively difficult, and the overall process is difficult for workers to operate, which is not conducive to operation.

[0004] To overcome the above shortcomings, the prior art (publication number CN221428662U) discloses a stator core chip, a stator core, and a motor. The stator core chip includes a toothed chip and a yoke chip formed in a complete circle. The toothed chip includes multiple toothed units arranged radially outward along the circumference, and at least one connecting groove is provided at the outer end of the multiple toothed units and / or the inner side of the yoke chip. The stator core chip also includes a connecting part, one end of which is used to connect with the toothed chip, and the other end of which is used to connect with the yoke chip. At least one end of the connecting part is used to mate with the connecting groove, and the groove width is smaller than the maximum width of the part of the connecting part that mates with the connecting groove. The stator core chip has a stable structure and is not easily deformed during use.

[0005] To overcome the above shortcomings, a prior art Chinese patent (publication number CN112671123B) discloses a stator core, a stator, and a motor. The stator core includes an inner stator core, which comprises multiple inner stator core sections connected sequentially to form a first annular structure. A slot is formed between two adjacent inner stator core sections. A first limiting structure is provided within the slot, and the first limiting structure is detachably connected to a second limiting structure for filling blocks used to fill the slot. And / or, a third limiting structure is provided on the outer circumferential surface of the inner stator core section, and the third limiting structure is detachably connected to a fourth limiting structure of the outer stator core, so that inner stator core sections of different sizes can be connected to the outer stator core. The stator core of this invention solves the problem of the narrow applicability of stator cores in the prior art.

[0006] While existing technologies can overcome the shortcomings mentioned above, other problems still exist during their operation, such as: unstable stator core dimensions, high internal stress, easy damage to the stator core during the processing of basic components, poor overall structural strength, and low service life of the equipment. Summary of the Invention

[0007] The purpose of this invention is to provide a straight-bar spliced ​​stator core for a frameless torque motor, in order to solve the problems mentioned in the background art, such as unstable stator core dimensions, large internal stress, easy damage to the entire stator core during the processing of basic components, poor overall structural strength, and short service life of the equipment.

[0008] To achieve the above objectives, the present invention provides the following technical solution: a frameless torque motor stator core with straight splicing, comprising a stator core body, wherein the initial state of the stator core body is a straight strip shape, and the stator cores are arranged in a straight line, the inner protrusion of the stator core body is the stator core tooth, and coils are wound sequentially on the stator core teeth, and after the coils are wound, the stator core body is integrally welded in a circle.

[0009] Furthermore, the number of stator core segments is N, the outer radius of the stator core body is D1, the inner radius of the stator core body is Di1, the central angle of a single stator core segment is α, and the vertical length of the stator core segments is L0, satisfying L0=N. {[(α) π D1) / 180] COSα {[tan(360° / Q1 A)] / }};A=2.8~3.2.

[0010] Furthermore, the maximum width of the stator core teeth is h1, and the minimum width of the stator core teeth is h2. The inner recess of the stator core body is a stator slot, and the width of the stator slot is h3, satisfying (h1 / h2). (D1 / Di1) COSα < 1.8 (h3 / h2)<(h1 / h2) (D1 / Di1) / COSα, 1.5<(h1 / h2)<2.

[0011] Furthermore, process holes are provided at the connection points of the stator core components, and these process holes can reduce local stress.

[0012] Furthermore, the stator slot is a straight slot, and a winding is provided on the inner side of the stator slot. The winding is a concentrated winding with a flat wire profile.

[0013] Furthermore, a welding groove is provided on the outer side of the stator core body, and the welding groove is semi-circular in shape.

[0014] Furthermore, one side of the stator core body roll-up connection is a notch, and the other side of the stator core body roll-up connection is a boss, so as to better enable splicing and positioning.

[0015] Furthermore, the end face of the stator core body and the stator core teeth are coated with insulating material, and the stator core teeth are trapezoidal in shape.

[0016] Furthermore, when the stator core body is cut, the two rows of stator core bodies are arranged in a staggered manner, which can reduce material waste and speed up the processing time.

[0017] Compared with the prior art, the beneficial effects of the present invention are: 1. The stator core body adopts a straight bar design with its split structure arranged in a straight line. Each split connection is provided with a process hole. These process holes are specifically used to eliminate internal stress generated during manufacturing and operation. This layout not only simplifies the production process but also ensures the uniformity and stability of the core and effectively reduces stress concentration. Furthermore, the coils are wound sequentially on the teeth of the stator core. After all the windings are completed, they are welded together in a circular shape. This process ensures the continuity and consistency of the windings. The winding operation is carried out in sequence, avoiding complex crossovers, improving production controllability, simplifying the winding process, increasing production speed and efficiency, and reducing the need for manual intervention, which helps to achieve large-scale manufacturing. Furthermore, welding grooves are provided on the outer side of the stator core body. When the protrusions and recesses on the left and right sides of the core are accurately aligned, welding is performed through the welding grooves. This design ensures precise alignment and firm connection of the connection points. The introduction of welding grooves optimizes the assembly process, reduces the risk of misalignment, enhances the integrity and mechanical strength of the stator core, ensures the stability and safety of the motor during operation, and reduces potential failure points.

[0018] 2. The stator slots adopt a straight slot design. Compared with the skewed slots, this structure makes the windings more evenly distributed in the slots, thereby improving the winding utilization and slot fill factor. The straight slot layout reduces the bending and loss of the windings, optimizes the electromagnetic performance, significantly improves the power density and energy conversion efficiency of the motor, and reduces copper loss, which helps to achieve higher output performance and energy efficiency. Furthermore, the winding wire is flat, which makes the winding method simple, direct, and fast. The overall process combines straight slot and high slot fill factor design, which together contribute to the output characteristics of high back electromotive force, large torque and high efficiency. The flat wire winding further optimizes space utilization and thermal management, and comprehensively improves the dynamic response and operating efficiency of the motor, enabling it to exhibit excellent torque output and energy utilization in various applications and meet high performance requirements. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the 18-slot, 20-pole rolled structure of the present invention.

[0020] Figure 2 This is a schematic diagram of the 18-slot 20-pole stator core split structure of the present invention.

[0021] Figure 3 This is a schematic diagram of the separate processing and arrangement structure of the 18-slot 20-pole stator core of the present invention.

[0022] Figure 4 This is a partially enlarged view of the 18-slot 20-pole stator core of the present invention.

[0023] Figure 5 This is a partially enlarged view of the split-rolled stator core of the 18-slot 20-pole invention.

[0024] Figure 6 This is a schematic diagram of the 36-slot, 32-pole rolled structure of the present invention.

[0025] Figure 7 This is a schematic diagram of the 36-slot, 32-pole stator core split structure of the present invention.

[0026] Figure 8 This is a schematic diagram of the separate processing and arrangement structure of the 36-slot 32-pole stator core of the present invention.

[0027] Figure 9 This is the curve showing the effect of the h1 / h2 ratio on the back EMF of the unloaded line in this invention.

[0028] Figure 10 This is the curve showing the effect of the h1 / h2 ratio on torque according to the present invention.

[0029] In the diagram: 1. Stator core body; 2. Stator core teeth; 3. Stator slot; 4. Process hole; 5. Welding groove; 6. Boss; 7. Notch. Detailed Implementation

[0030] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0031] Example 1: As Figures 1-10The technical solution shown is a frameless torque motor with a straight-bar spliced ​​stator core. In order to solve the problem of poor overall structure and easy damage, the following is disclosed: stator core body 1, the initial state of stator core body 1 is straight bar shape, and the stator core is arranged in a straight line. The inner protrusion of stator core body 1 is stator core tooth 2, and the stator core tooth 2 is wound with coils in sequence. After the coils are wound, the stator core body 1 is welded in a circle.

[0032] The stator core consists of N segments, with an outer radius of D1 and an inner radius of Di1. The central angle of a single stator core segment is α, and the vertical length of the stator core segments arranged is L0, satisfying L0 = N. {[(α) π D1) / 180] COSα {[tan(360° / Q1 A)] / }};A=2.8~3.2.

[0033] The maximum width of the stator core tooth 2 is h1, and the minimum width of the stator core tooth 2 is h2. The inner recess of the stator core body 1 is the stator slot 3, and the width of the stator slot 3 is h3, which satisfies (h1 / h2). (D1 / Di1) COSα < 1.8 (h3 / h2)<(h1 / h2) (D1 / Di1) / COSα, 1.5<(h1 / h2)<2.

[0034] A process hole 4 is provided at the connection of the stator core components, and the process hole 4 can reduce local stress.

[0035] The stator slot 3 is a straight slot, and a winding is provided on the inner side of the stator slot 3. The winding is a concentrated winding and the wire type is flat wire.

[0036] The stator core body 1 has a welding groove 5 on its outer side, and the welding groove 5 is semi-circular in shape.

[0037] One side of the stator core body 1 has a notch 7 at the rolled connection point, and the other side has a boss 6, which makes it easier to splice and position.

[0038] Both the end face of the stator core body 1 and the stator core teeth 2 are coated with insulating material, and the stator core teeth 2 are trapezoidal in shape.

[0039] When the stator core body 1 is cut, the two rows of stator core bodies 1 are arranged in a staggered manner, which can reduce material waste and speed up the processing time.

[0040] The stator core body 1 is a straight bar type, and the stator core is divided into sections arranged in a straight line. Each stator core section has a process hole 4 at the connection point. The process hole 4 is used to relieve stress. The coil is wound sequentially on the stator core teeth 2. After all the winding is completed, the whole body is welded in a circle. The stator core body 1 has a welding groove 5 on the outside. When the left and right sides of the stator core body 1 have the corresponding protrusions 6 and recesses 7, they are welded through the welding groove 5. The stator slot 3 is a straight slot. Compared with the skewed slot winding, it has a higher utilization rate and a higher slot fill factor. The winding wire is a flat wire, which is simple to wind, fast, efficient, has a high slot fill factor, high back electromotive force, large torque, and high efficiency.

[0041] Multiple stator cores are arranged in a straight line, with process holes 4 opened at the connection points of each component. This design actively releases and eliminates internal stress in the early stages of manufacturing. By eliminating this pre-stress, a dimensionally stable and low-stress foundation component is provided for subsequent processes, thereby effectively improving the structural reliability and long-term dimensional stability of the stator core body 1. During the winding stage, the coils are wound sequentially and independently onto the teeth 2 of each straight stator core. After all winding is completed, the entire straight core is then encircled and welded to form a complete circular stator. This transforms the complex winding operation in a confined space into a simple and efficient linear operation, significantly improving the winding speed and slot fill factor. This design reduces manufacturing complexity. The solidification principle of the stator core body 1 relies on specially designed welding grooves 5 on its outer side. When the core is enclosed in a circle, the protrusions 6 and recesses 7 on both sides are precisely fitted and positioned. High-strength welding is then performed through these welding grooves 5 to permanently connect the separate cores into one unit. This ensures that the combined components achieve mechanical strength and structural integrity comparable to an integral core, providing a robust and low-resistance path for establishing the magnetic field, thus guaranteeing the smooth and safe operation of the motor. The core of the electromagnetic performance lies in the use of straight slot design and flat wire windings. The straight slot structure allows the winding conductors to be embedded more directly and tightly into the slots. Compared to skewed slots, it reduces the length of the winding ends, improving conductor utilization and slot fill factor. Combined with the flat wire profile, it achieves lower DC resistance and a better heat dissipation area. These two factors work together to significantly improve the motor's back electromotive force level and torque output capability.

[0042] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A frameless torque motor stator core with straight-bar splicing, comprising a stator core body (1), characterized in that: The initial state of the stator core body (1) is a straight bar shape, and the stator core is arranged in a line. The inner protrusion of the stator core body (1) is the stator core tooth (2), and the stator core tooth (2) is wound with coils in sequence. After the coils are wound, the stator core body (1) is welded in a circle as a whole.

2. The frameless torque motor stator core with straight-bar splicing as described in claim 1, characterized in that: The number of stator core segments is N, and the outer radius of the stator core body (1) is D1, and the inner radius of the stator core body (1) is Di1. The central angle of a single stator core segment is α, and the vertical length of the stator core segments is L0, satisfying L0=N. {[(α) π D1) / 180] COSα {[tan(360° / Q1 A)] / }};A=2.8~3.

2.

3. The frameless torque motor stator core with straight-bar splicing as described in claim 1, characterized in that: The maximum width of the stator core teeth (2) is h1, and the minimum width of the stator core teeth (2) is h2. The inner recess of the stator core body (1) is the stator slot (3), and the width of the stator slot (3) is h3, which satisfies (h1 / h2). (D1 / Di1) COSα < 1.8 (h3 / h2)<(h1 / h2) (D1 / Di1) / COSα, 1.5<(h1 / h2)<2.

4. The frameless torque motor stator core with straight-bar splicing as described in claim 1, characterized in that: The stator core is provided with a process hole (4) at the split connection, and the process hole (4) can reduce local stress.

5. A frameless torque motor stator core with straight-bar splicing as described in claim 3, characterized in that: The stator slot (3) is a straight slot, and a winding is provided on the inner side of the stator slot (3), and the winding is a concentrated winding with a flat wire.

6. The frameless torque motor stator core with straight-bar splicing as described in claim 1, characterized in that: The stator core body (1) has a welding groove (5) on its outer side, and the welding groove (5) is semi-circular in shape.

7. A frameless torque motor stator core with straight-bar splicing as described in claim 1, characterized in that: The stator core body (1) has a notch (7) on one side of the rolled connection and a boss (6) on the other side, so that it can be better spliced ​​and positioned.

8. A frameless torque motor stator core with straight-bar splicing as described in claim 1, characterized in that: The end face of the stator core body (1) and the stator core teeth (2) are both coated with insulating material, and the stator core teeth (2) are trapezoidal teeth.

9. A frameless torque motor stator core with straight-bar splicing as described in claim 1, characterized in that: When the stator core body (1) is cut, the two rows of stator core bodies (1) are arranged in a staggered manner, which can reduce material waste and speed up the processing time.

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