Synchronous machine stator structure and method of manufacturing the same

Abstract

The application discloses a synchronous motor stator structure and a manufacturing method thereof. The synchronous motor stator structure comprises a plurality of stator cores, a plurality of winding assemblies and a glue pouring layer. Each stator core is a circular ring segment. An outer diameter surface of each stator core is at least partially formed with a support portion. The support portion is located at a middle portion of the stator core along the circumferential direction of the stator core. Adjacent two stator cores are inserted into each other along the circumferential direction. The plurality of winding assemblies are sleeved on the stator cores. Two winding assemblies are arranged between any adjacent two support portions. The two winding assemblies are respectively abutted to the two support portions at one end of the winding assemblies which is away from each other. A gap is formed between the two winding assemblies at one end of the winding assemblies which is close to each other. The plurality of winding assemblies and the plurality of stator cores are matched to form a ring structure. The glue pouring layer is annular and covers the ring structure. The glue pouring layer does not fill the gap. Through the above arrangement, the occurrence of air corona caused by excessive local electric field strength can be avoided, and the service life of the synchronous motor stator structure is improved.

Description

Technical Field

[0001] This application relates to the field of motor technology, and in particular to a synchronous motor stator structure and its manufacturing method. Background Technology

[0002] High-voltage motors can carry higher voltages, thus reducing the current intensity within the motor and consequently decreasing line losses, making them advantageous for applications in high-power equipment. However, the stator windings of high-voltage motors can exhibit excessively high local electric field strength, leading to air corona discharge.

[0003] To avoid air corona discharge in the windings that could affect motor performance, existing high-voltage motors use non-magnetic teeth to support the windings. However, the complex internal structure of high-voltage motors increases the precision requirements for the machining of non-magnetic teeth. Furthermore, the assembly of non-magnetic materials into non-magnetic magnets can create numerous gaps, resulting in a large number of air gaps inside the motor. These air gaps can increase the generation of air corona discharge, thereby reducing the lifespan of the stator. Summary of the Invention

[0004] In order to overcome the shortcomings of the prior art, the purpose of this application is to provide a synchronous motor stator structure and its manufacturing method.

[0005] To achieve the above objectives, this application adopts the following technical solution: In a first aspect, embodiments of this application provide a synchronous motor stator structure, including: Multiple stator cores, each stator core being an annular segment, with at least a portion of the outer diameter surface of each stator core having a support portion located at the center of the stator core along its circumference, and adjacent stator cores being interlocked with each other along their circumference. Multiple winding assemblies are sleeved on the stator core. Two winding assemblies are provided between any two adjacent support parts. The ends of the two winding assemblies that are opposite to each other abut against the two support parts respectively, and a gap is formed between the ends of the two winding assemblies that are close to each other. Multiple winding assemblies are combined with multiple stator cores to form a ring structure; Each winding assembly includes multiple abutting winding modules, each winding module comprising: Toroidal winding; Two support structures, each of which at least partially surrounds and contacts the stator core, each support structure forming a receiving slot for accommodating at least a portion of the annular winding, the opening of the receiving slot being located on the outside of the support structure away from the stator core, so that there is a gap between the annular winding and the stator core. The potting layer is ring-shaped and covers the ring structure; the potting layer does not fill the gaps.

[0006] In one possible implementation, the gap overlaps with the insertion positions of the two adjacent stator cores radially along the stator core.

[0007] In one possible implementation, each winding module further includes two air-cooling pipes, both of which are annular and are respectively attached to both sides of the annular winding along the circumference of the stator core. Each air-cooling pipe is supported by two support structures. Each air-cooling pipe has an exhaust pipe and an intake pipe on both sides along the axial direction of the stator core, and the exhaust pipe and intake pipe extend to both sides of the potting layer along its axial direction.

[0008] In one possible implementation, each support structure has a cooling trough that accommodates at least part of the air-cooled pipes, with the opening of the cooling trough located on the inner sidewall of the accommodating trough.

[0009] In one possible implementation, the two support structures are respectively provided with an air outlet groove for accommodating at least part of the air outlet pipe and an air inlet groove for accommodating at least part of the air inlet pipe. On the same support structure, the air outlet groove is connected to the cooling groove of the corresponding support structure, and the air inlet groove is connected to the cooling groove of the corresponding support structure.

[0010] In one possible implementation, each support structure includes a first support member and a second support member, which are distributed circumferentially along the stator core. A first protrusion structure is formed on the side of the first support member that contacts the stator core, and a second protrusion structure connected to the first protrusion structure is formed on the side of the second support member that contacts the stator core. The first and second protrusion structures form the bottom surface of a receiving groove on the surface away from the stator core. The first and second protrusion structures cause a gap between the annular winding and the stator core.

[0011] In one possible implementation, the air-cooled duct is arranged around two support structures and connected to the surfaces of the two support structures opposite to the stator core.

[0012] In one possible implementation, the synchronous motor stator structure also includes a wrapping layer, through which the air-cooled duct located between the two support structures and the annular winding are fixed and bonded.

[0013] In one possible implementation, the synchronous motor stator structure further includes a stator housing and a stator inner housing. The stator housing is arranged around and connected to the potting layer, multiple support parts abut against the inner wall of the stator housing, and multiple winding assemblies are arranged around and connected to the stator inner housing.

[0014] In one possible implementation, the potting layer has a plurality of first air cooling holes and a plurality of second air cooling holes extending through the potting layer along its axial direction. Each first air cooling hole and each second air cooling hole are located on both sides of the insertion position of two adjacent stator cores to form at least a partial gap. The air flowing through the first air cooling holes and the second air cooling holes directly contacts the stator cores.

[0015] In one possible implementation, the potting layer has a plurality of third air cooling holes that penetrate the potting layer along its axial direction. Each third air cooling hole is located inside the stator core and overlaps with a support portion along the radial direction of the stator core. The air flowing through the third air cooling hole can directly contact the stator core.

[0016] In one possible implementation, the stator core has connecting protrusions and connecting slots formed on both sides of its circumference, and two adjacent stator cores are connected by connecting protrusions and connecting slots; the outer contour of the connecting protrusion is consistent with the inner contour of the connecting slot.

[0017] Secondly, embodiments of this application provide a method for manufacturing a synchronous motor stator structure, applicable to the aforementioned synchronous motor stator structure. The manufacturing method includes a hollow annular container for dispensing glue, with an opening for holding and dispensing glue formed on one side of the container along its axial direction. The manufacturing method includes the following steps: Place the stator support inside the bottom of the glue container; The annular structure is placed inside the glue-filling container and supported by the stator support. The stator support overlaps only with the support part of the annular structure along the axial direction of the annular structure, and the support part of the annular structure abuts against the inner wall of the glue-filling container. Multiple support plates are placed between the inner wall of the glue-filling container and the stator core, at least a portion of the multiple support plates are located in the gap between the winding assemblies, and at least a portion of the multiple support plates are located on the side of the stator core away from the support portion. Pour the adhesive into the adhesive container; Remove the ring structure containing the potting layer and separate the multiple support plates from the ring structure.

[0018] In the aforementioned synchronous motor stator structure, multiple winding assemblies and multiple stator cores cooperate to form a ring structure, and an adhesive layer is used to cover the ring structure. The adhesive layer is an insulating material, which allows the ring windings to be completely covered by the insulating material, thereby improving the insulation performance of the ring windings. This improves the uniformity of the battery intensity generated by the winding assemblies and avoids the generation of air gaps in the synchronous motor stator structure, thus preventing excessive local electric field intensity and air corona discharge, and further improving the service life of the synchronous motor stator structure. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the synchronous motor stator structure provided in an embodiment of this application.

[0020] Figure 2 This is a schematic diagram of the annular structure of the synchronous motor stator provided in an embodiment of this application.

[0021] Figure 3 This is a schematic diagram of the winding module of the synchronous motor stator structure provided in the embodiments of this application.

[0022] Figure 4 This is an exploded view of the winding module of the synchronous motor stator structure provided in the embodiments of this application.

[0023] Figure 5 This is a schematic diagram of the support structure for the synchronous motor stator structure provided in an embodiment of this application.

[0024] Figure 6 This is a schematic diagram of the stator core of the synchronous motor stator structure provided in the embodiments of this application.

[0025] Figure 7 This is a schematic diagram of the combination of the annular structure and the potting container of the synchronous motor stator structure provided in the embodiments of this application.

[0026] Figure 8 This is a schematic diagram of the combination of the annular structure, support member, and support plate of the synchronous motor stator structure provided in the embodiments of this application.

[0027] Figure 9 A flowchart illustrating the manufacturing method of the synchronous motor stator structure provided in this application embodiment. Detailed Implementation

[0028] To enable those skilled in the art to better understand the present application, the technical solutions in specific embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings.

[0029] It should be noted that the terms "first," "second," and similar terms used in this application specification and claims do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Similarly, "a" or "one," and similar terms do not indicate a quantity limitation, but rather indicate the presence of at least one. "A plurality" or "several" indicates at least two. Unless otherwise stated, terms such as "front," "back," "left," "right," "lower," and / or "upper" are for illustrative purposes only and are not limited to a location or spatial orientation. Terms such as "comprising" or "including" indicate that the elements or objects preceding "comprising" encompass the elements or objects listed following "comprising" or "including" and their equivalents, and do not exclude other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect.

[0030] The singular forms “a,” “the,” and “the” used in this application specification and appended claims may also include one or more, unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used herein describes the relationship between related objects, indicating that three relationships may exist, for example, A and / or B, which can represent: A alone, A and B simultaneously, or B alone, where A and B can be singular or plural.

[0031] like Figure 1 and Figure 2 As shown, this application provides a synchronous motor stator structure 400, which includes a plurality of stator cores 41 and a plurality of winding assemblies 42. The stator cores 41 support the winding assemblies 42, which are capable of generating an induced magnetic field.

[0032] Specifically, each stator core 41 is a circular segment, and adjacent stator cores 41 are interlocked circumferentially. Multiple winding assemblies 42 are fitted onto the stator cores 41, forming a ring structure 401, thereby creating a ring-shaped armature winding. This configuration, compared to a straight armature winding, avoids the windings crossing at the stator ends. It should be noted that the synchronous motor stator structure 400 of this application is used in high-voltage operating conditions, where the winding assemblies 42 carry a high-voltage current, resulting in a high electric field. If the windings cross at the stator ends, the electric field at the stator ends will be further concentrated, leading to excessively high electric field strength at the stator ends and causing corona discharge of the gas at the stator ends. Therefore, this application sets the synchronous motor stator structure 400 as a ring armature winding, which can avoid the winding assembly 42 from being cross-wound at the end of the synchronous motor stator structure 400, so as to avoid the electric field strength at the end of the synchronous motor stator structure 400 being too large and causing air corona, thereby improving the safety and service life of the synchronous motor stator structure 400.

[0033] More specifically, the synchronous motor stator structure 400 also includes a potting layer 43, which is ring-shaped and covers the ring structure 401. The potting layer 43 can fix and support the stator core 41 and the winding assembly 42.

[0034] In some embodiments, the potting layer 43 is epoxy resin. After curing, the epoxy resin has high structural strength, enabling the potting layer 43 to support the stator core 41 and the winding assembly 42. Furthermore, the epoxy resin has insulating properties, allowing an insulating layer to be formed on the outer surfaces of the stator core 41 and the winding assembly 42. This insulating layer can uniformly distribute the electric field intensity generated by the winding assembly 42, preventing excessively high local electric field intensity that could lead to air corona discharge, thereby improving the service life of the synchronous motor stator structure 400.

[0035] Secondly, by using a potting method, this application allows the liquid potting compound to penetrate into the gaps of the annular structure 401, thereby improving the adhesion between the potting layer 43 and the winding assembly 42, and thus improving the adhesion between the winding assembly 42 and the insulation layer. This prevents gaps between the winding assembly 42 and the potting layer 43 from forming air gaps within the synchronous motor stator structure 400. Since the electric field generated by the winding assembly 42 will cause electric field distortion in the air gap, the electric field strength at the air gap will increase sharply, leading to air corona discharge. Therefore, by using a potting method, this application can prevent the formation of such air gaps within the synchronous motor stator structure 400, thus avoiding a sharp increase in the electric field and preventing air corona discharge within the synchronous motor stator structure 400.

[0036] Furthermore, if insulating sheets are spliced ​​together to insulate the annular structure 401, a large number of tiny gaps in the annular structure 401 would require numerous tiny sheets to fill these gaps to prevent the aforementioned air gaps from appearing in the stator structure. However, these tiny sheets increase the assembly difficulty of the stator structure, and the high machining precision of the tiny sheets also increases the machining difficulty of the stator structure. Additionally, the splicing method results in poor connection strength between the insulating sheets and the annular structure 401, leading to poor vibration resistance of the stator structure. Therefore, this application uses an encapsulation layer 43 to fill the tiny gaps in the annular structure 401 without the need for sheet splicing. This reduces the assembly difficulty of the synchronous motor stator structure 400 and eliminates the need for machining tiny sheets, thus reducing the machining difficulty of the synchronous motor stator structure 400. Moreover, the encapsulation method allows the encapsulation layer 43 and the annular structure 401 to be integrated components, which improves the connection strength of the synchronous motor stator structure 400 and consequently enhances its vibration resistance.

[0037] In this embodiment, at least a portion of the outer diameter surface of each stator core 41 is formed with a support portion 411, which is located at the center of the stator core 41 along its circumference. Two winding assemblies 42 are disposed between any two adjacent support portions 411, with the opposite ends of the two winding assemblies 42 abutting against the two support portions 411 respectively. A gap 402 is formed between the adjacent ends of the two winding assemblies 42.

[0038] In some embodiments, the synchronous motor stator structure 400 is a three-phase alternating stator structure, with three stator cores 41. Three sets of winding assemblies 42 are provided, namely U-phase windings, V-phase windings, and W-phase windings. Each set of winding assemblies 42 includes a first winding segment and a second winding segment electrically connected. The first and second winding segments are symmetrically arranged about the center of the annular structure 401 and fitted onto different stator cores 41 to form an annular armature winding. Along the circumference of the annular structure 401, winding assemblies 42 of different phases are fitted on both sides of the support portion 411 on each stator core 41, and winding assemblies 42 of different phases are also fitted on both sides of each gap 402.

[0039] With this configuration, the support part 411 can separate the winding assemblies 42 of different phases, which is beneficial for fitting the winding assemblies 42 onto the stator core 41.

[0040] Secondly, when potting the annular structure 401 with the potting layer 43, the annular structure 401 is placed inside the potting container, and the support part 411 can abut against the inner wall of the potting container, so that there is a gap between the winding assembly 42 and the inner wall of the potting container. This is beneficial for the potting layer 43 to wrap the winding assembly 42, thereby improving the insulation of the winding assembly 42 and improving the uniformity of the electric field generated by the winding assembly 42, so as to avoid the generation of air corona.

[0041] In some embodiments, the support portion 411 is formed by extending the stator core 41 away from its center of curvature, so that the support portion 411 and the stator core 41 are integral components, which helps to improve the connection strength between the support portion 411 and the stator core 41, thereby improving the structural strength of the stator core 41, and further improving the structural strength of the synchronous motor stator structure 400.

[0042] Furthermore, when potting the annular structure 401 with the potting layer 43, the potting layer 43 does not fill the gap 402. This arrangement allows the gap 402 to be located between winding components 42 of different phases. Since the potential difference of the electric field generated by the winding components 42 of different phases on both sides of the gap 402 is large, the insulation requirement at the gap 402 is high. In this application, the air flowing in the gap 402 can achieve air insulation between the winding components 42 of different phases. Since the insulation of air is better than that of the solid potting layer 43, the insulation requirement at the gap 402 is met, so as to avoid insufficient insulation performance at the gap 402 leading to the breakdown of the insulation material by the electric field, thereby improving the service life of the synchronous motor stator structure 400.

[0043] like Figures 2 to 4 As shown, in this application, each winding assembly 42 includes a plurality of mutually abutting winding modules 421. Each winding module 421 includes a ring winding 4211 and two support structures 4212. The ring winding 4211 is capable of being connected to a high-voltage power supply to generate an induced magnetic field, and the support structures 4212 are used to support the ring winding 4211.

[0044] Specifically, both support structures 4212 at least partially surround and contact the stator core 41, and each support structure 4212 forms a receiving groove 4212a to accommodate at least a portion of the annular winding 4211. The receiving groove 4212a facilitates the assembly of the annular winding 4211 with the support structure 4212.

[0045] More specifically, the opening of the receiving groove 4212a is located on the outer side of the support structure 4212 away from the stator core 41, and the bottom of the receiving groove 4212a is spaced from the stator core 41, so that the annular winding 4211 and the stator core 41 are spaced apart. This arrangement allows the potting layer 43 to fill between the annular winding 4211 and the stator core 41 through the gap, facilitating the potting layer 43 to wrap around the annular winding 4211. This allows the insulating material to wrap around the annular winding 4211, preventing air corona discharge caused by an air gap between the potting layer 43 and the annular winding 4211, thereby improving the service life of the synchronous motor stator structure 400.

[0046] In some embodiments, the toroidal winding 4211 is made of multi-strand coils molded with Litz wire, which can reduce the skin effect and proximity effect under high-frequency alternating current, thereby significantly reducing the AC resistance and copper loss of the toroidal winding 4211. Furthermore, each toroidal winding 4211 includes two coils arranged in parallel. When connecting the coils, the coils in the same row are connected in series first, followed by the coils in the same line, so that the coil leads can be positioned on the outside of the coils, i.e., the leads of the toroidal winding 4211 can be positioned on the outside of the toroidal winding 4211, which facilitates the wiring of the toroidal winding 4211.

[0047] In some embodiments, the coil within the toroidal winding 4211 is filled with epoxy resin to improve the insulation of the toroidal winding 4211. Secondly, a mica insulation layer and anti-corona tape are wrapped around the toroidal winding 4211, and VPI (Vacuum Pressure Impregnation) is used to perform insulating impregnation on the toroidal winding 4211, further improving the insulation of the toroidal winding 4211, thereby improving the uniformity of the electric field generated by the toroidal winding 4211.

[0048] In this application, the support structure 4212 is made of a non-magnetic and non-conductive material, i.e., the support structure 4212 is made of an insulating material so that the toroidal winding 4211 can be wrapped with the insulating material, thereby improving the uniformity of the electric field generated by the toroidal winding 4211. For example, the support structure 4212 is made of epoxy resin or fiberglass.

[0049] In summary, the synchronous motor stator structure 400 of this application forms a ring armature winding, which can prevent the winding assembly 42 from generating excessive electric field strength, thereby avoiding air corona discharge within the synchronous motor stator structure 400 due to excessive electric field strength. Secondly, the support structure 4212 supports the ring winding 4211, allowing the ring winding 4211 to be completely encapsulated by the potting layer 43 and the support structure 4212. This facilitates complete coverage of the ring winding 4211 with insulating material, improving the insulation performance of the ring winding 4211. This enhances the uniformity of the battery strength generated by the winding assembly 42 and prevents air gaps within the synchronous motor stator structure 400, thus avoiding excessive local electric field strength that could lead to air corona discharge and ultimately extending the service life of the synchronous motor stator structure 400.

[0050] like Figure 4 and Figure 5 As shown, in one embodiment, each winding module 421 also includes two air-cooling pipes 4213. Both air-cooling pipes 4213 are annular and are respectively attached to both sides of the annular winding 4211 along the circumference of the stator core 41. Air can circulate in the air-cooling pipes 4213, which is beneficial for cooling the annular winding 4211 to avoid damage caused by excessive temperature of the annular winding 4211, thereby improving the service life of the annular winding 4211.

[0051] Specifically, each air-cooled pipe 4213 is supported by two support structures 4212 to improve the installation stability of the air-cooled pipe 4213, thereby facilitating the fit between the air-cooled pipe 4213 and the annular winding 4211 located on the support structure 4212.

[0052] More specifically, each air-cooled pipe 4213 has an exhaust pipe 4213a and an intake pipe 4213b on both sides along the axial direction of the stator core 41. The exhaust pipe 4213a and the intake pipe 4213b extend to both sides of the potting layer 43 along its axial direction. That is, the exhaust pipe 4213a and the intake pipe 4213b are not covered by the potting layer 43, so that the air-cooled pipe 4213 can take in air through the intake pipe 4213b and then take out air through the exhaust pipe 4213a, thereby realizing air circulation in the air-cooled pipe 4213, which is beneficial to heat dissipation of the annular winding 4211.

[0053] In this application, the air-cooled pipe 4213 is made of a non-magnetic and non-conductive material, that is, the air-cooled pipe 4213 is made of an insulating material so that the toroidal winding 4211 can be wrapped with the insulating material, thereby improving the uniformity of the electric field generated by the toroidal winding 4211. For example, the air-cooled pipe 4213 is made of epoxy resin.

[0054] As an optional implementation, each support structure 4212 has a cooling groove 4212b that accommodates at least a portion of the air-cooled pipe 4213, with the opening of the cooling groove 4212b located on the inner wall of the accommodating groove 4212a. This arrangement allows the cooling groove 4212b to limit the position of the air-cooled pipe 4213 and facilitates its fit against the annular winding 4211, thereby improving the cooling effect on the annular winding 4211.

[0055] Specifically, the two support structures 4212 are respectively provided with an air outlet groove 4212c and an air inlet groove 4212d. The air outlet groove 4212c accommodates at least a portion of the air outlet pipe 4213a, and the air inlet groove 4212d accommodates at least a portion of the air inlet pipe 4213b. More specifically, on the same support structure 4212, the air outlet groove 4212c connects to the cooling groove 4212b of the corresponding support structure 4212, and the air inlet groove 4212d connects to the cooling groove 4212b of the corresponding support structure 4212. This arrangement prevents interference between the air outlet pipe 4213a and the corresponding support structure 4212 through the air outlet groove 4212c, and prevents interference between the air inlet pipe 4213b and the corresponding support structure 4212 through the air inlet groove 4212d, thereby facilitating the assembly of the air-cooled pipe 4213 with the support structure 4212.

[0056] In one embodiment, each support structure 4212 includes a first support member 4212e and a second support member 4212f. The first support member 4212e and the second support member 4212f are distributed circumferentially along the stator core 41. This configuration, with its split support structure 4212, facilitates the installation of the annular winding 4211 onto the support structure 4212.

[0057] Specifically, a first protrusion 4212g is formed on the side of the first support member 4212e that contacts the stator core 41, and a second protrusion 4212h is formed on the side of the second support member 4212f that contacts the stator core 41. The second protrusion 4212h is connected to the first protrusion 4212g, and both the first and second protrusions have a groove bottom surface (receiving groove 4212a) formed on their surfaces facing away from the stator core 41. This arrangement allows the annular winding 4211 to be fitted onto the first and second protrusions 4212g and 4212h.

[0058] More specifically, the first protrusion structure 4212g and the second protrusion structure 4212h create a gap between the annular winding 4211 and the stator core 41, thereby creating a gap between the annular winding 4211 and the stator core 41, which facilitates the encapsulation layer 43 wrapping the annular winding 4211, thereby improving the electric field uniformity of the annular winding 4211.

[0059] In another embodiment, the air-cooled duct 4213 is arranged around the two support structures 4212 and connected to the surfaces of the two support structures 4212 opposite to the stator core 41. With this arrangement, the air-cooled duct 4213 can be installed without having cooling grooves 4212b, air outlet grooves 4212c, and air inlet grooves 4212d on the support structures 4212, which simplifies the manufacturing process of the support structures 4212.

[0060] In one implementation, the synchronous motor stator structure 400 also includes a wrapping layer 44. The air-cooled pipe 4213 located between the two support structures 4212 and the annular winding 4211 are fixed and bonded together by the wrapping layer 44. This arrangement allows the wrapping layer 44 to constrain the air-cooled pipe 4213 and the annular winding 4211, ensuring a stable fit and thus improving the heat dissipation effect on the annular winding 4211.

[0061] In this application, the wrapping layer 44 is made of a non-magnetic and non-conductive material, i.e., the wrapping layer 44 is made of an insulating material, so that the toroidal winding 4211 can be wrapped with the insulating material, thereby improving the uniformity of the electric field generated by the toroidal winding 4211. For example, the wrapping layer 44 is made of insulating paper impregnated with epoxy resin.

[0062] In one implementation, the insertion positions of the gap 402 and the two adjacent stator cores 41 overlap radially along the stator core 41. Since the winding assemblies 42 installed on the two adjacent stator cores 41 have different phases, the gap 402 located at the insertion position can be located between winding assemblies 42 of different phases to meet the insulation requirements of winding assemblies 42 of different phases.

[0063] In one embodiment, the potting layer 43 has a plurality of first air-cooling holes (not shown) and a plurality of second air-cooling holes (not shown) extending axially through the potting layer 43. Along the radial direction of the annular structure 401, each first air-cooling hole and each second air-cooling hole are located on both sides of the insertion position of two adjacent stator cores 41 to form at least a partial gap 402. This arrangement facilitates airflow through the first and second air-cooling holes, achieving air insulation at the gap 402 while allowing the flowing air to facilitate heat dissipation from the synchronous motor stator structure 400.

[0064] Specifically, the air flowing through the first and second air cooling holes directly contacts the stator core 41. This arrangement allows the air in the gap 402 to directly contact the stator core 41, thereby improving the heat exchange efficiency between the air and the stator core 41 and thus enhancing the heat dissipation effect on the synchronous motor stator structure 400.

[0065] like Figure 1As shown, in one embodiment, the synchronous motor stator structure 400 further includes a stator outer shell 45 and a stator inner shell 46. The stator outer shell 45 is disposed around and connected to the potting layer 43, and multiple support portions 411 abut against the inner wall of the stator outer shell 45, which helps to improve the structural strength of the synchronous motor stator structure 400. Multiple winding assemblies 42 are disposed around and connected to the stator inner shell 46. This arrangement, through the stator outer shell 45 and the stator inner shell 46, can protect the annular structure 401 and the potting layer 43, which helps to improve the service life of the synchronous motor stator structure 400.

[0066] In one embodiment, the potting layer 43 has a plurality of third air-cooling holes (not shown) extending axially through it. Specifically, each third air-cooling hole is located inside the stator core 41, and each third air-cooling hole overlaps with a support portion 411 radially with the stator core 41. This arrangement allows air to circulate within the third air-cooling holes, which is beneficial for cooling the stator core 41 and thus for heat dissipation of the synchronous motor stator structure 400.

[0067] More specifically, the air flowing through the third air cooling hole can directly contact the stator core 41. This arrangement can improve the heat exchange effect between the air in the third air cooling hole and the stator core 41, further improving the heat dissipation effect on the synchronous motor stator structure 400.

[0068] like Figure 6 As shown, in one embodiment, the stator core 41 has connecting protrusions 412 and connecting slots 413 formed on both sides of its circumference. Two adjacent stator cores 41 are connected by connecting protrusions 412 and connecting slots 413. This arrangement allows for the assembly of two adjacent stator cores 41 through connecting protrusions 412 and connecting slots 413, which is beneficial for the assembly of the synchronous motor stator structure 400.

[0069] In this embodiment, the stator core 41 has connecting protrusions 412 and connecting grooves 413 formed on its two circumferential sides. When two adjacent stator cores 41 are connected by the connecting protrusions 412 and connecting grooves 413, the sides of the two adjacent stator cores 41 can fit together, thereby improving the connection tightness of the two adjacent stator cores 41 and thus improving the structural stability of the synchronous motor stator structure 400.

[0070] In one embodiment, the stator core 41 has chamfered portions 414 formed on both sides along its axial direction. These chamfered portions 414 are used to reduce the non-uniform electric field strength of the air in contact with the stator core 41, thereby avoiding air corona discharge. It should be noted that if the stator core is perpendicular to its axial direction on both sides, sharp edges will form on both sides of the stator core. These sharp edges have an excessively strong field concentration effect, resulting in a large electric field strength at the sharp edges of the stator core, thus causing air corona discharge. Therefore, this application forms smooth, rounded chamfered portions on both sides of the stator core 41 along its axial direction, which can reduce the field concentration effect, thereby reducing the electric field strength and avoiding air corona discharge.

[0071] Specifically, the chamfered portion 414 is located at the junction of the inner diameter surface of the stator core 41 and the side surface 415, and / or the chamfered portion 414 is located at the junction of the outer diameter surface of the stator core 41 and the side surface. The side surface 415 refers to the two surfaces of the stator core 41 distributed axially along the synchronous motor stator structure 400.

[0072] like Figures 7 to 9 As shown, this application provides a method for manufacturing a synchronous motor stator structure 400. The method includes a hollow annular filling container 47 for filling the annular structure 401. Specifically, the filling container 47 has an opening 471 for placing and filling materials on one side along its axial direction. The annular structure 401 and the filling material are placed into the filling container 47 through the opening 471.

[0073] More specifically, the manufacturing method includes the following steps: S401: Place the stator support 48 on the inner bottom of the glue container 47; In step S401, the stator support 48 can prevent the annular structure 401 from directly contacting the bottom of the glue container 47, so that the side of the annular structure 401 that is in contact with the bottom of the glue container 47 cannot be glued, thereby facilitating the glue layer 43 to cover the annular structure 401.

[0074] S402: The annular structure 401 is placed inside the potting container 47 and supported by the stator support 48.

[0075] The stator support 48 overlaps only with the support portion 411 of the annular structure 401 along the axial direction of the annular structure 401, and the support portion 411 of the annular structure 401 abuts against the inner wall of the glue-filling container 47.

[0076] In step S402, contact between the stator support 48 and the winding assembly 42 is avoided, preventing the winding assembly 42 from contacting the potting compound, which would otherwise prevent the potting compound from contacting the winding assembly 42. This facilitates the potting compound layer 43 encapsulating the winding assembly 42. Secondly, the support portion 411 prevents the winding assembly 42 from abutting against the inner wall of the potting container 47, which would otherwise prevent the winding assembly 42 from contacting the potting compound, further facilitating the potting compound layer 43 (see reference). Figure 1 ) Wrapping winding assembly 42.

[0077] S403: A plurality of support plates 49 are placed between the inner wall of the glue container 47 and the stator core 41, at least a portion of the plurality of support plates 49 being located within the gap 402 between the winding assemblies 42, and at least a portion of the plurality of support plates 49 being located on the side of the stator core 41 away from the support portion 411.

[0078] In step S403, the support plate 49 located in the gap 402 between the winding assemblies 42 can prevent glue from being injected into the gap 402. The gap 402 includes a first gap located outside the stator core 41 and a second gap located inside the stator core 41. The support plate 49 includes a first support plate 491, a second support plate 492, and a third support plate 493. The first support plate 491 is located in the first gap and abuts against the outer wall of the stator core 41. The second support plate 492 is located in the second gap and abuts against the inner wall of the stator core 41. The third support plate 493 is located on the side of the stator core 41 away from the support portion 411 and abuts against the inner wall of the stator core 41.

[0079] S404: Pour the glue into the glue container 47.

[0080] In step S404, the potting compound is epoxy resin.

[0081] S405: Remove the annular structure 401 containing the potting layer 43 and separate the multiple support plates 49 from the annular structure 401.

[0082] In step S405, separating the support plate 49 located in the gap between the winding assemblies 42 allows the formation of a first air-cooling hole and a second air-cooling hole communicating with the gap on the potting layer 43. Separating the support plate 49 located on the side of the stator core 41 opposite to the support portion 411 allows the formation of a third air-cooling hole on the potting layer 43.

[0083] It should be understood that those skilled in the art can make improvements or modifications based on the above description, and all such improvements and modifications should fall within the protection scope of the appended claims.

Claims

1. A stator structure for a synchronous motor, characterized in that, include: Multiple stator cores, each stator core being an annular segment, and at least a portion of the outer diameter surface of each stator core having a support portion located at the center of the stator core along its circumference, with adjacent stator cores being interlocked with each other along their circumference; Multiple winding assemblies are sleeved on the stator core. Two winding assemblies are provided between any two adjacent support portions. The ends of the two winding assemblies that are opposite to each other abut against the two support portions respectively, and a gap is formed between the ends of the two winding assemblies that are close to each other. The plurality of winding assemblies and the plurality of stator cores are coupled to form a ring structure; Each of the winding assemblies includes a plurality of mutually abutting winding modules, each winding module comprising: Toroidal winding; Two support structures, each of which at least partially surrounds and contacts the stator core, each of which forms a receiving groove for accommodating at least a portion of the annular winding, the opening of which is located on the outside of the support structure away from the stator core, such that there is a gap between the annular winding and the stator core. A potting layer, which is ring-shaped and covers the ring structure, does not fill the gaps.

2. The synchronous motor stator structure according to claim 1, characterized in that, The gap overlaps with the insertion positions of the two adjacent stator cores along the radial direction of the stator core.

3. The synchronous motor stator structure according to claim 1, characterized in that, Each winding module also includes two air-cooling pipes, both of which are annular and respectively attached to both sides of the annular winding along the circumference of the stator core. Each air-cooling pipe is supported by two support structures. Each of the air-cooled pipes has an outlet pipe and an inlet pipe formed on both sides along the axial direction of the stator core, and the outlet pipe and the inlet pipe extend to both sides of the potting layer along its axial direction.

4. The synchronous motor stator structure according to claim 3, characterized in that, Each of the support structures has a cooling groove that accommodates at least a portion of the air-cooled pipes, and the opening of the cooling groove is located on the inner sidewall of the accommodating groove.

5. The synchronous motor stator structure according to claim 4, characterized in that, The two support structures are respectively provided with an air outlet groove for accommodating at least part of the air outlet pipe and an air inlet groove for accommodating at least part of the air inlet pipe. On the same support structure, the air outlet groove is connected to the cooling groove of the corresponding support structure, and the air inlet groove is connected to the cooling groove of the corresponding support structure.

6. The synchronous motor stator structure according to claim 5, characterized in that, Each of the support structures includes a first support member and a second support member, which are distributed circumferentially along the stator core. A first protrusion structure is formed on the side of the first support member that contacts the stator core, and a second protrusion structure connected to the first protrusion structure is formed on the side of the second support member that contacts the stator core. The bottom surface of the receiving groove is formed on the surface of the first protrusion structure and the second protrusion structure away from the surface of the stator core. The first protrusion structure and the second protrusion structure create a gap between the annular winding and the stator core.

7. The synchronous motor stator structure according to claim 3, characterized in that, The air-cooled duct is arranged around the two support structures and connected to the surfaces of the two support structures opposite to the stator core.

8. The synchronous motor stator structure according to claim 3, characterized in that, The synchronous motor stator structure also includes a wrapping layer, and the air-cooled pipe located between the two support structures is fixed and attached to the annular winding through the wrapping layer.

9. The synchronous motor stator structure according to claim 1, characterized in that, The synchronous motor stator structure further includes a stator outer shell and a stator inner shell. The stator outer shell is arranged around and connected to the potting layer. The plurality of supporting parts abut against the inner wall of the stator outer shell, and the plurality of winding assemblies are arranged around and connected to the stator inner shell.

10. The synchronous motor stator structure according to claim 1, characterized in that, The potting layer has a plurality of first air cooling holes and a plurality of second air cooling holes that penetrate the potting layer along its axial direction. Each first air cooling hole and each second air cooling hole is located on both sides of the insertion position of two adjacent stator cores to form at least part of the gap. The air flowing through the first air cooling hole and the second air cooling hole directly contacts the stator core.

11. The synchronous motor stator structure according to claim 1, characterized in that, The potting layer has a plurality of third air cooling holes that penetrate the potting layer along its axial direction. Each third air cooling hole is located inside the stator core. Each third air cooling hole overlaps with a support portion along the radial direction of the stator core. The air flowing through the third air cooling hole can directly contact the stator core.

12. The synchronous motor stator structure according to claim 1, characterized in that, The stator core has connecting protrusions and connecting grooves formed on both sides of its circumference, and two adjacent stator cores are connected by the connecting protrusions and connecting grooves. The outer contour of the connecting protrusion is consistent with the inner contour of the connecting groove.

13. A method for manufacturing a synchronous motor stator structure, applicable to the synchronous motor stator structure as described in any one of claims 1 to 12, characterized in that, The manufacturing method includes a hollow annular glue-filling container, wherein an opening for holding and filling glue is formed on one side along its axial direction. The manufacturing method includes the following steps: A stator support is placed at the bottom inside the glue container; The annular structure is placed inside the glue container and supported by the stator support member. The stator support member overlaps only with the support portion of the annular structure along the axial direction of the annular structure, and the support portion of the annular structure abuts against the inner wall of the glue container. A plurality of support plates are placed between the inner wall of the glue container and the stator core, at least a portion of the plurality of support plates being located in the gap between the winding assemblies, and at least a portion of the plurality of support plates being located on the side of the stator core away from the support portion. The adhesive is poured into the adhesive container; Remove the ring structure containing the potting layer and separate the plurality of support plates from the ring structure.

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