electric machine

Abstract

An electric motor includes a housing, a stator assembly, a rotor assembly, a fan blade, and a tail cover. The stator assembly includes an annular stator core and coil groups wound in the coil slots of the stator core. The stator core is composed of multiple independent "I"-shaped stator units assembled into a closed annular shape. The outer and inner transverse sides of each stator unit are arc-shaped, with the arc length of the outer transverse side being longer than that of the inner transverse side. A groove and a boss are respectively provided on both sides of the outer transverse side. In two adjacent stator units, the boss of one stator unit can fit into the groove of another stator unit. The coil groups are divided into multiple groups, the number of which corresponds to the number of stator units. Each group of coils is wound in the coil slots on both sides of the stator unit, forming a stator unit winding. All stator unit windings are sequentially assembled to form a closed-loop stator assembly, and then welded and fixed at the joint of two adjacent stator units. The coils of the coil groups are connected. This invention has a more rational structure and higher working efficiency.

Description

Technical Field

[0001] This invention relates to an electric motor, and more particularly to an electric motor used in water tanks and swimming pools. Background Technology

[0002] We know that coils are wound on the stator of an electric motor, and magnets are installed on the rotor. Currently, most motor stators are wound in a circular fashion. This means that when the circular stator is mounted on a winding machine, the number of turns to be wound is set based on calculations, experiments, and power conversions. Winding begins in one pair of coil slots. After the set number of turns is completed, the winding machine slightly rotates the stator before winding the next pair of coil slots, thus winding the appropriate number of turns section by section. Due to limitations imposed by the stator structure and the winding machine, the actual space available for winding in the coil slots is limited. Therefore, it is impossible to wind a very full coil in the slots. Consequently, the coil slot fill rate of a circular stator winding is low, which affects the motor's efficiency. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of the prior art and provide a motor with a more reasonable structure and higher working efficiency, which greatly improves and optimizes the efficiency of the motor by increasing the slot fill factor of the winding.

[0004] To solve the aforementioned technical problems, the present invention adopts the following technical solution:

[0005] An electric motor includes a housing portion, a stator assembly, a rotor assembly, a fan blade, and a tail cover, wherein:

[0006] The housing portion includes a housing, a front cover and a rear cover located at both ends of the housing;

[0007] The stator assembly is installed and fixed inside the housing. It includes an annular stator core and coil groups wound in the coil slots of the stator core. The stator core is composed of multiple independent "I"-shaped stator units spliced ​​together to form a closed ring. The outer and inner horizontal sides of the stator unit are arc-shaped, and the arc length of the outer horizontal side is longer than that of the inner horizontal side. Grooves and bosses are respectively provided on both sides of the outer horizontal side. In two adjacent stator units, the boss of one stator unit can fit into the groove of the other stator unit. The coil groups are divided into multiple groups, the number of which corresponds to the number of stator units. Each group of coils is wound in the coil slots on both sides of the stator unit to form a stator unit winding. All stator unit windings are spliced ​​together one by one to form a closed-loop stator assembly, and then welded and fixed at the joint of two adjacent stator units. The coils of the coil groups are connected.

[0008] The rotor assembly includes a motor shaft, a rotor core sleeved on the motor shaft, a front bearing and a rear bearing disposed on the motor shaft, and a magnetic bearing disposed on the rotor core; the front bearing and the rear bearing are respectively disposed in the front end cover and the rear end cover.

[0009] The fan blade is connected to the motor shaft of the rotor assembly, and the air drawn in blows onto the housing.

[0010] The tail cover covers the fan blade and has an air inlet.

[0011] In the improved version of the above motor, a splicing and bonding surface is provided on the side wall of the outer horizontal edge; the outer horizontal edge of the two adjacent stator units is welded and fixed at the joint.

[0012] The improved motor design also includes a frequency converter control structure. This structure comprises a frequency converter circuit board, a circuit board heat sink, a frequency converter operator, a protective cover, a touchscreen, a junction box, and a transparent cover for the protective cover. The frequency converter circuit board is installed and fixed into the circuit board heat sink, which is then mounted along the motor's axial direction on the outside of the rear end cover. The frequency converter operator is installed inside the protective cover, and the motor's operation is controlled by a touchscreen mounted on the surface of the protective cover. The protective cover is installed and fixed onto the upper surfaces of the housing and the circuit board heat sink. The junction box and the transparent cover are detachably or openably mounted on the protective cover. The motor shaft passes sequentially through the rear end cover, the frequency converter circuit board, and the circuit board heat sink before connecting to the fan blade.

[0013] In the improved version of the motor, multiple air intake channels are provided axially on the housing, rear end cover and circuit board heat sink, and the air intake channels at their corresponding positions are straight.

[0014] In the improved version of the above motor, the magnetic tiles are in multiple pairs, each corresponding to a magnetic pole, and are embedded in the rotor core; each pair of magnetic tiles is of different lengths; the rotor core is provided with multiple pairs of magnetic tile embedding holes for embedding each pair of magnetic tiles respectively; a pair of magnetic tile embedding holes are pointed but separated by ribs and are not interconnected.

[0015] In the improved version of the above-mentioned motor, in a pair of magnetic tile embedding holes, one magnetic tile embedding hole is longer than the other magnetic tile embedding hole, and the longer embedding hole extends towards the center of the rotor core.

[0016] In the improved version of the above motor, the thickness of the rib is between 2-6mm.

[0017] Compared with the prior art, the beneficial effects of the present invention are as follows: Since the stator core of the stator assembly is composed of multiple "I"-shaped stator units spliced ​​into a closed ring, coils can be wound in the coil slots on both sides of each stator unit before splicing them into the stator core. Since the coil slots are open outwards and there is no interference from adjacent stator units, it is very simple and easy to wind wires on the stator units, and the coil slots can be filled as much as possible, as long as the space of the coil slots is not exceeded. Therefore, the slot fill factor of the coil slots is high. Under the same size and specification requirements of the stator core, and under the same conditions in other aspects, the higher the slot fill factor, the higher the efficiency of the motor. Therefore, the structure of the present invention is more reasonable and the working efficiency is higher.

[0018] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments: Attached Figure Description

[0019] Figure 1 This is a three-dimensional illustration of an embodiment of the present invention. Figure 1 ;

[0020] Figure 2 This is a three-dimensional illustration of an embodiment of the present invention. Figure 2 ;

[0021] Figure 3 This is an assembly diagram of an embodiment of the present invention;

[0022] Figure 4 This is a three-dimensional schematic diagram of the stator assembly according to an embodiment of the present invention;

[0023] Figure 5 This is a front view schematic diagram of the stator assembly according to an embodiment of the present invention;

[0024] Figure 6 This is a three-dimensional schematic diagram of a portion of the stator assembly according to an embodiment of the present invention;

[0025] Figure 7 This is a three-dimensional schematic diagram of two stator units according to an embodiment of the present invention;

[0026] Figure 8 This is a front view schematic diagram of the rotor assembly according to an embodiment of the present invention;

[0027] Figure 9 This is a front view schematic diagram of the rotor core according to an embodiment of the present invention;

[0028] Figure 10 yes Figure 9 A magnified view of part I;

[0029] Figure 11 This is a schematic diagram of the disassembly and assembly of the upper part of the frequency converter control structure according to an embodiment of the present invention. Detailed Implementation

[0030] This invention relates to an electric motor, such as... Figures 1 to 7 As shown, it includes a housing part 1, a stator assembly 2, a rotor assembly 3, a fan blade 4, and a tail cover 5, wherein:

[0031] The housing part 1 includes a housing 11, a front cover 12 and a rear cover 13 provided at both ends of the housing 11;

[0032] The stator assembly 2 is installed and fixed inside the housing 11, and includes an annular stator core 21 and coil groups wound in the coil slots 211 of the stator core 21. The stator core 21 is composed of multiple independent "I"-shaped stator units 212 spliced ​​together to form a closed ring. The outer horizontal edge 2121 and the inner horizontal edge 2122 of the stator unit 212 are arc-shaped, and the arc length of the outer horizontal edge 2121 is longer than that of the inner horizontal edge 2122. A groove 21211 and a boss 21212 are respectively provided on both sides of the outer horizontal edge 2121. In two adjacent stator units 212, its The boss 21212 of one stator unit 212 can fit into the groove 21211 of another stator unit 212; the coil group 22 is divided into multiple groups, the number of which corresponds to the number of stator units 212; each group of coils is wound in the coil slots 211 on both sides of the stator unit 212 to form a stator unit winding; all stator unit windings are spliced ​​one by one to form a closed-loop stator assembly 2, and then welded and fixed at the joint of two adjacent stator units 212; the coil connection of the coil group 22 is consistent with the current requirements for the coil connection of the stator assembly of the motor.

[0033] The rotor assembly 3 includes a motor shaft 31, a rotor core 32 sleeved on the motor shaft 31, a front bearing 33 and a rear bearing 34 disposed on the motor shaft 31, and a magnetic tile 35 disposed on the rotor core 32; the front bearing 33 and the rear bearing 34 are respectively disposed in the front end cover 12 and the rear end cover 13.

[0034] The fan blade 4 is connected to the motor shaft 31 of the rotor assembly 3, and the air drawn in blows onto the housing 11.

[0035] The tail cover 5 covers the fan blade 4 and has an air inlet 51 on it.

[0036] As can be seen from the above, since the stator core 21 of the stator assembly 2 is designed as a closed ring composed of multiple "I"-shaped stator units 212 spliced ​​together, coils can be wound in the coil slots 211 on both sides of each stator unit 212 before splicing them into the stator core. Since the coil slots are open outwards and there is no interference from adjacent stator units 212, it is very simple and easy to wind wires on the stator unit 212, and the wires can be wound as full as possible in the coil slots, as long as they do not exceed the space of the coil slots. Therefore, the slot fill factor of the coil slots 211 is high. Under the same size and specification requirements of the stator core, and under the same conditions in other aspects, the higher the slot fill factor, the higher the efficiency of the motor. Therefore, the structure of the present invention is more reasonable and the working efficiency is higher.

[0037] In this embodiment, as Figure 7 As shown, to facilitate positioning after two adjacent stator units 212 are spliced ​​together, a splicing and fitting surface 21213 is provided on the side wall of the outer transverse edge 2121. This surface can be a plane (as in this embodiment) or a concave or convex arc surface, etc. When the grooves 21211 and bosses 21212 of two adjacent stator units 212 are fitted together, their splicing and fitting surfaces 21213 are brought closer together until they fit together. This process is repeated one by one to complete the splicing of the stator assembly, greatly facilitating the splicing process. After splicing, the joints on the outer walls of the outer transverse edges 2121 of the two adjacent stator units are welded and fixed.

[0038] Current variable frequency motors generally separate the motor and the frequency converter, requiring external wiring for frequency control, which is inconvenient. This embodiment, as a preferred implementation, [does not specify the preferred method]. Figures 1 to 3As shown in Figure 11, the motor and frequency converter are integrated into a single variable frequency motor. For this purpose, a frequency conversion control structure 6 is also included. The frequency conversion control structure 6 includes a frequency conversion circuit board 61, a circuit board heat sink 62, a frequency conversion operator 63, a protective cover 64, a touch screen 65, a junction box 66, and a transparent cover 67. After the frequency conversion circuit board 61 is installed (e.g., with screws) into the circuit board heat sink 62, the circuit board heat sink 62 is mounted along the axial direction of the motor on the outside of the rear end cover 13. The frequency conversion operator 63... After being installed inside the protective cover 64, the operation of the motor is controlled by the touch screen 65 mounted on the surface of the protective cover 64. The protective cover 64 is fixedly mounted to the upper surface of the housing 11 and the circuit board heat sink 62. The junction box 66 and the transparent cover 67 of the protective cover are detachably or openably mounted on the protective cover 64. When the inverter needs to be operated, the transparent cover is opened or lifted (here, the transparent cover is a flip-top type) to operate the touch screen 65. When the motor needs to be used, the junction box 66 is opened and the power cord is connected. The motor shaft 31 passes through the rear end cover 13, the inverter circuit board 61 and the circuit board heat sink 62 in sequence before connecting to the fan blade 4. The tail cover 5 is fixed together with the circuit board heat sink 62.

[0039] The front cover 12, housing 11, rear cover 13, and circuit board heat sink 62 are fixedly connected together with long bolts 7; to further improve the heat dissipation effect of the motor and circuit board, such as Figure 3 As shown, multiple air inlet channels 111, 131, and 621 are respectively provided axially on the housing 11, rear end cover 13, and circuit board heat sink 62, with the corresponding air inlet channels being straight through. In this way, the air drawn in by the fan blade 4 passes through the air inlet channels 111, 131, and 621 of the housing 11, rear end cover 13, and circuit board heat sink 62 in sequence and is blown out from the air outlet of the air inlet channel 111 of the housing 11. This is better than the current method of most motors using horizontal heat dissipation fins on the outer wall of their housings for heat dissipation. This not only improves the heat dissipation effect of the motor (because in most current motors, the air drawn in by the fan blades blows onto the nearest section of the heat dissipation fins, rather than the entire length of the heat dissipation fins), but also reduces noise (the sound generated by the motor is not transmitted directly, but is transmitted after being separated by multiple air inlet channels, which can greatly reduce noise).

[0040] In this embodiment, as Figure 8 , 9As shown in Figure 10, currently, most motor magnets are glued to the outer peripheral wall of the rotor core. This poses a risk of the magnets falling off during operation, causing the motor to malfunction. Furthermore, we know that the strength of a magnet is directly proportional to its size. In this preferred embodiment, the magnets 35 are arranged in multiple pairs, each corresponding to a magnetic pole (in this embodiment, there are 8 magnetic poles, therefore 8 pairs of magnets), embedded within the rotor core 32. Each pair of magnets 35 has a different length, meaning they are not symmetrically distributed. The rotor core 32 has multiple pairs of magnet embedding holes 321 for embedding each pair of magnets 35. Each pair of magnet embedding holes 321 is pointed but separated by ribs 322, which help to form a more complete integral structure and increase the rigidity of the rotor core 32. Sufficient to withstand centrifugal force at high speeds and prevent being thrown off and rubbing against the inner diameter of the stator core. Therefore, the rib 322 ensures sufficient overall rigidity and structural stability of the rotor core 32, and also reduces the deformation and resonance of the rotor core itself, resulting in a more stable rotation sound. In this embodiment, in a pair of magnetic tile embedding holes 321, one magnetic tile embedding hole 321 is longer than the other magnetic tile embedding hole 321. The longer embedding hole extends further toward the center of the rotor core (i.e., deeper toward the center) than the other hole, so that the pair of magnetic tile embedding holes 321 form an approximate lowercase letter "y" shape, but the two strokes of this letter are not connected. The portion of the magnetic tile installed in the extension at the lower end of the pair of Y-shaped magnetic tile embedding holes increases the volume of the magnetic tile, thus effectively increasing the magnetic force. A small portion of this magnetic force precisely compensates for the reactive magnetic force leaking from the rib path towards the shaft. This not only does not reduce the performance of the rotor core but also enhances the magnetic force. Therefore, the non-intersecting pair of Y-shaped magnetic tile embedding holes, after the magnetic tiles are installed, can ensure sufficient rigidity of the rotor core while also enhancing the magnetic performance of the core. Considering that the ribs need sufficient strength but cannot be too thick to affect the size and volume of the magnetic tile, the thickness of the rib 322 is typically between 2-6 mm.

[0041] In the description of this invention, it should be understood that terms such as "length," "width," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0042] Although the present invention has been described in detail with reference to the above embodiments, it will be apparent to those skilled in the art that various changes or modifications can be made to the invention without departing from the principles and spirit of the invention as defined by the claims. Therefore, the detailed description of the embodiments in this disclosure is for illustrative purposes only and is not intended to limit the invention; rather, the scope of protection is defined by the content of the claims.

Claims

1. An electric motor, comprising a housing portion (1), a stator assembly (2), a rotor assembly (3), a fan blade (4), and a tail cover (5), characterized in that: The housing part (1) includes a housing (11), a front end cover (12) and a rear end cover (13) provided at both ends of the housing (11). The stator assembly (2) is installed and fixed inside the housing (11), and includes an annular stator core (21) and coil groups (22) wound in the coil slots (211) of the stator core (21). The stator core (21) is composed of multiple independent "I"-shaped stator units (212) spliced ​​into a closed ring. The outer horizontal edge (2121) and inner horizontal edge (2122) of the stator unit (212) are arc-shaped, and the arc length of the outer horizontal edge (2121) is longer than that of the inner horizontal edge (2122). A groove (21211) and a boss (21212) are respectively provided on both sides of the outer horizontal edge (2121). In two adjacent stator units (212), the boss (21212) of one stator unit (212) can fit into the groove (21211) of the other stator unit (212); the coil group (22) is divided into multiple groups, the number of which corresponds to the number of stator units (212); each group of coils is wound in the coil slots (211) on both sides of the stator unit (212) to form a stator unit winding; all stator unit windings are spliced ​​one by one to form a closed-loop stator assembly (2) and then welded and fixed at the joint of two adjacent stator units (212); the coils of the coil group (22) are connected; The rotor assembly (3) includes a motor shaft (31), a rotor core (32) sleeved on the motor shaft (31), a front bearing (33) and a rear bearing (34) disposed on the motor shaft (31), and a magnetic tile (35) disposed on the rotor core (32); the front bearing (33) and the rear bearing (34) are respectively disposed in the front end cover (12) and the rear end cover (13); The fan blade (4) is connected to the motor shaft (31) of the rotor assembly (3), and the air drawn in blows onto the housing (11); The tail cover (5) covers the fan blade (4) and has an air inlet (51) on it.

2. The motor according to claim 1, characterized in that: A splicing and bonding surface (21213) is provided on the side wall of the outer horizontal edge (2121); it is welded and fixed at the joint of the outer wall of the outer horizontal edge (2121) of two adjacent stator units.

3. The motor according to claim 1, characterized in that: It also includes a frequency converter control structure (6); the frequency converter control structure (6) includes a frequency converter circuit board (61), a circuit board heat sink (62), a frequency converter operator (63), a protective cover (64), a touch screen (65), a junction box (66), and a transparent cover (67) of the protective cover; after the frequency converter circuit board (61) is installed and fixed in the circuit board heat sink (62), the circuit board heat sink (62) is installed on the outside of the rear end cover (13) along the axial direction of the motor; the frequency converter operator (63) is installed on the protective cover. Inside the protective cover (64), the operation of the motor is controlled by a touch screen (65) installed on the surface of the protective cover (64); the protective cover (64) is installed and fixed to the upper surface of the housing (11) and the circuit board heat sink (62); the junction box (66) and the transparent cover (67) of the protective cover are detachably or openably installed on the protective cover (64); the motor shaft (31) passes through the rear end cover (13), the frequency converter circuit board (61) and the circuit board heat sink (62) in sequence and is connected to the fan blade (4).

4. The motor according to claim 3, characterized in that: Multiple air inlet channels (111, 131, 621) are provided axially on the housing (11), the rear end cover (13) and the circuit board heat sink (62), respectively, and the air inlet channels at their corresponding positions are straight.

5. The motor according to any one of claims 1 to 4, characterized in that: The magnetic tiles (35) have multiple pairs corresponding to a magnetic pole, and they are embedded in the rotor core (32); each pair of magnetic tiles (35) is of different lengths; the rotor core (32) is provided with multiple pairs of magnetic tile embedding holes (321) for embedding each pair of magnetic tiles (35); a pair of magnetic tile embedding holes (321) are pointed but separated by ribs (322) and are not interconnected.

6. The motor according to claim 5, characterized in that: In a pair of said magnetic tile embedding holes (321), one magnetic tile embedding hole (321) is longer than the other magnetic tile embedding hole (321), and the longer embedding hole extends toward the center of the rotor core more than the other hole.

7. The motor according to claim 5 or 6, characterized in that: The thickness of the rib (322) is between 2 and 6 mm.

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