Insulation skeleton, stator assembly and motor

Abstract

This invention provides an insulating frame, a stator assembly, and a motor. The insulating frame includes an outer wall (1), inner teeth (2), and a frame bridge (3) connecting the outer wall (1) and the inner teeth (2). The axial height of the inner teeth (2) is lower than the axial height of the outer wall (1). According to the insulating frame of this invention, the axial deformation of the inner teeth can be effectively reduced, avoiding the problem of the insulating frame interfering with the rotor.

Description

Technical Field

[0001] The invention belongs to the technical field of motors, and in particular relates to an insulating frame, a stator assembly and a motor. Background Art

[0002] As the main part for supporting and insulating the stator winding of the motor, the insulation skeleton is required to have a structural strength with small enough deformation and no breakage, and the electrical clearance and creepage distance must meet safety standards. It is also required to be reliably matched with the various parts of the stator. The current insulation skeleton has the following three prominent problems in long-term use:

[0003] 1. The height of the inner teeth of the insulation frame is too large, resulting in excessive maximum radial deformation of the inner teeth under the extrusion load of the winding coil, even exceeding the inner diameter of the stator core, causing interference with the rotor;

[0004] 2. To ensure that the slot insulation does not push out of the insulation frame during assembly, as a avoidance measure, the slot of the insulation frame is larger than the slot of the stator core. There is a large step difference between the matching surface of the frame and the axial end face of the core. The slot insulation is under great pressure and deformation at the matching surface of the frame core, and there is a risk of the slot insulation being crushed.

[0005] 3. The wire head of the first turn of the coil winding does not avoid the subsequent coils. The wire head bears the pressure of all subsequent windings, is severely deformed under pressure, and there is a risk of breakage. Summary of the invention

[0006] Therefore, the technical problem to be solved by the present invention is to provide an insulating frame, a stator assembly and a motor, which can effectively reduce the axial deformation of the inner teeth and avoid the problem of the insulating frame interfering with the rotor.

[0007] In order to solve the above problems, the present invention provides an insulating frame, including an outer wall, inner teeth and a frame bridge connecting the outer wall and the inner teeth, wherein the axial height of the inner teeth is lower than the axial height of the outer wall.

[0008] Preferably, the height h of the inner tooth meets h=b+c, ​​wherein b is the maximum height of the winding wire package in contact with the inner tooth, and c is the axial thickness of the skeleton bridge.

[0009] Preferably, the inner tooth height h satisfies h=b+c+x, wherein b is the maximum height of the winding wire package in contact with the inner tooth, c is the axial thickness of the skeleton bridge, and x is the maximum rebound height of the winding end in contact with the inner tooth.

[0010] Preferably, the axial height of the inner tooth is 60% to 70% of the axial height of the outer wall.

[0011] Preferably, a skeleton groove is formed between the outer wall, the inner tooth guard and the skeleton bridge, and a groove insulation layer is provided in the skeleton groove.

[0012] Preferably, step grooves are formed on both sides of the skeleton bridge in the circumferential direction, and the groove insulation layer is arranged in the step grooves.

[0013] Preferably, the step height of the step groove is a, wherein a is greater than or equal to the thickness of the groove insulating layer.

[0014] Preferably, there is an axial distance d between the trench insulating layer and the side wall of the step trench.

[0015] Preferably, d=(axial height upper deviation+axial height upper deviation of slot insulation layer+axial height difference of stator core before and after winding) / 2+axial thickness upper deviation of skeleton bridge.

[0016] Preferably, an embedding groove for placing an incoming wire end is provided on the inner side wall of the outer wall.

[0017] Preferably, the depth of the embedding groove is greater than or equal to the wire diameter of the incoming wire end.

[0018] Preferably, the outer side wall of the outer wall is provided with convex ribs at positions corresponding to the embedding grooves.

[0019] Preferably, the incoming wire end includes N enameled wires wound in parallel, and the width of the embedding groove is greater than or equal to N times the diameter of the enameled wire.

[0020] According to another aspect of the present invention, a stator assembly is provided, comprising a stator core and an insulating frame arranged on the stator core, wherein the insulating frame is the insulating frame mentioned above.

[0021] According to another aspect of the present invention, a motor is provided, comprising a stator core and an insulating frame arranged on the stator core, wherein the insulating frame is the insulating frame mentioned above.

[0022] The insulating frame provided by the present invention comprises an outer wall, an inner tooth and a frame bridge connecting the outer wall and the inner tooth, and the axial height of the inner tooth is lower than the axial height of the outer wall. The insulating frame of the present invention can make the axial height of the inner tooth lower than the axial height of the outer wall by reducing the axial ineffective height of the inner tooth. Therefore, compared with the prior art, the axial height of the inner tooth can be reduced, and the maximum axial deformation of the inner tooth of the insulating frame can be reduced, thereby reducing the risk of the inner tooth exceeding the inner circle of the stator core, avoiding the problem of the insulating frame interfering with the rotor, and improving the working reliability of the motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a three-dimensional structural diagram of a stator assembly in the prior art;

[0024] Figure 2 It is a diagram showing the matching structure of the insulating frame and the stator core of the stator assembly in the prior art;

[0025] Figure 3 for Figure 2 AA section structural diagram;

[0026] Figure 4 for Figure 3 The enlarged structure diagram at Q of ;

[0027] Figure 5 It is a three-dimensional structural diagram of an insulating frame in the prior art;

[0028] Figure 6 for Figure 5 B-direction view;

[0029] Figure 7 This is a winding effect diagram of an insulating skeleton in the prior art;

[0030] Figure 8 is a three-dimensional structural diagram of a stator assembly according to an embodiment of the present invention;

[0031] Fig. 9 This is a diagram showing the matching structure of the insulating frame and the stator core of the stator assembly according to an embodiment of the present invention;

[0032] Fig.10 for Fig. 9 AA section structural diagram;

[0033] Fig.11 for Fig.10 The enlarged structure diagram at Q of ;

[0034] Fig.12 is a three-dimensional structural diagram of an insulating frame in an embodiment of the present invention;

[0035] Fig.13 for Fig.12 B-direction view;

[0036] Fig.14 This is a diagram showing the winding effect of the insulating skeleton according to an embodiment of the present invention.

[0037] The reference numerals are as follows:

[0038] 1. Outer wall; 2. Inner tooth; 3. Frame bridge; 4. Slot insulation layer; 5. Step slot; 6. Embedded slot; 7. Inlet wire end; 8. Stator core. DETAILED DESCRIPTION

[0039] See also Figures 1 to 7As shown, the existing motor stator includes a stator core 8, an insulating frame located at both ends of the stator core 8 in the axial direction, slot insulation lined in the stator core slots, a plurality of windings evenly distributed on the stator core teeth, and a lead wire assembly. Among them, the insulating frame and the slot insulation together constitute an insulating support structure between the winding and the stator core 8. In order to ensure that the motor rotor maintains a specific gap with the stator in the inner hole of the stator and operates stably, the inner tooth guard part of the insulating frame is required not to exceed the inner diameter of the stator core; in order to ensure electrical safety, the insulating support structure is not allowed to have defects such as holes and damage.

[0040] The existing insulating frame includes an outer wall 1, an inner tooth 2 and a frame bridge 3 connecting the inner and outer structures. Figure 6 The B view shows that the inner teeth 2 of the skeleton are at the same height or nearly at the same height as the outer wall 1; the outer wall 1 corresponding to the multiple inner teeth 2 is provided with winding entry and exit slots, which are arranged in pairs or individually according to the winding relationship, wherein in the circumferential direction, the entry slot is close to the skeleton bridge 3, and the exit slot is close to the symmetric center line of the skeleton slot.

[0041] The outer wall 1 of the insulating skeleton, the inner teeth 2 and the skeleton bridge 3 connecting the inner and outer structures, the above structure forms a plurality of skeleton slots evenly distributed corresponding to the stator core structure, the slot insulation is placed in the stator core and the corresponding insulating skeleton slots, and is restricted from moving by the axial and axial slot insulation limit structures located on the insulating skeleton, thereby forming a continuous and uninterrupted insulating structure layer between the stator core 8 and the winding. There is a gap a between the slot insulation and the insulating skeleton at the axial end face of the core and the insulating skeleton. The winding pressure of the winding coil will force the slot insulation to deform in the direction of eliminating the gap a, and there is a risk of the slot insulation end being crushed.

[0042] In addition, the insulating frame is not equipped with a structure to avoid the wire end of the first turn of the winding, and the wire end of the first turn of the winding does not avoid the subsequent coils. The wire end bears the pressure of all subsequent windings, is severely deformed under pressure, and there is a risk of breakage.

[0043] In order to solve the above problems in the prior art, Figures 8 to 14 As shown, according to an embodiment of the present invention, the insulating skeleton includes an outer wall 1, inner teeth 2 and a skeleton bridge 3 connecting the outer wall 1 and the inner teeth 2, and the axial height of the inner teeth 2 is lower than the axial height of the outer wall 1.

[0044] The insulating skeleton of the present invention can make the axial height of the inner guard tooth 2 lower than the axial height of the outer wall 1 by reducing the axial ineffective height of the inner guard tooth 2. Therefore, compared with the prior art, it can reduce the axial height of the inner guard tooth 2 and reduce the maximum axial deformation of the inner guard tooth 2 of the insulating skeleton, thereby reducing the risk of the inner guard tooth 2 exceeding the inner circle of the stator core, avoiding the problem of the insulating skeleton interfering with the rotor, and improving the working reliability of the motor.

[0045] The setting height of the inner guard tooth 2 is based on the ability to effectively prevent the winding from overflowing. Generally speaking, along the direction from the outer wall 1 to the inner guard tooth 2, the winding is distributed in a trapezoidal shape in the wire groove, that is, the closer to the inner guard tooth 2, the lower the height of the winding. Therefore, the winding height that contacts the inner guard tooth 2 is the lowest and is much lower than the axial height of the outer wall 1. For the inner guard tooth 2 that is higher than the winding height, this part is redundant and is prone to cause large deformation. Therefore, this part can be cut off, and only the height that can form an effective stop for the winding is retained. The lower the height of the inner guard tooth 2, the smaller the deformation, and the less likely it is to cause excessive deformation and interfere with the rotor.

[0046] Preferably, the height h of the inner guard teeth 2 satisfies h=b+c, ​​where b is the maximum height of the winding coil in contact with the inner guard teeth 2, and c is the axial thickness of the skeleton bridge 3, thereby reducing the invalid inner guard teeth height that produces excessive radial deformation. Due to the extrusion of the stator winding coil tensioning force, the inner guard teeth 2 of the insulating skeleton will have a deformation along the stator radial direction toward the axis, and the maximum position of the deformation is at the top of the inner guard teeth 2, set to Δt. If Δt is too large, the inner guard teeth will exceed the inner diameter of the stator core and interfere with the rotor. According to the similar triangle theory, under the premise of the same winding, the force on the inner guard teeth remains unchanged, then Δt∝h. In addition, since the cross-section of the stator winding is a trapezoidal structure with a wide outside and a narrow inside, the effective height of the inner guard teeth 2 depends on the maximum height of the inner circle of the winding; by analyzing the winding structure and the needle winding process, it can be seen that the dimension b of the inner guard teeth structure of the skeleton limited by the width of the stator slot is the theoretical maximum height of the inner circle of the winding coil. From the geometric relationship, it can be known that the theoretical limit value of the effective height of the inner tooth guard 2 is h=b+c.

[0047] See also Figure 7 and Fig.14 As shown, Figure 7 Δt0 is the deformation amount of the inner toothbrush 2 when the structure in the prior art is subjected to force. Fig.14 : shows the deformation amount △t1 generated when the inner tooth guard 2 is subjected to force after adopting the structure of the embodiment of the present invention. It can be seen from the figure that after adopting the structure of the embodiment of the present invention, the deformation amount generated when the inner tooth guard 2 is subjected to force is significantly reduced.

[0048] Preferably, the height h of the inner tooth 2 satisfies h=b+c+x, where b is the maximum height of the winding coil in contact with the inner tooth 2, c is the axial thickness of the skeleton bridge 3, and x is the maximum rebound height of the winding end in contact with the inner tooth 2. In this embodiment, the rebound amount of the winding end is taken into account, so the design height of the inner tooth 2 can be increased to ensure that the height of the inner tooth 2 is sufficient to support all the inner coils of the winding, which can more effectively avoid the problem that the inner tooth 2 is too low to effectively block the winding wire, and further increase the reliability of the motor.

[0049] Preferably, the axial height of the inner guard tooth 2 is 60% to 70% of the axial height of the outer wall 1, which can ensure that the inner guard tooth 2 has sufficient height to effectively block the winding and limit the winding, and can also avoid the inner guard tooth 2 being too high, effectively reducing the problem of internal super-interference rotor caused by excessive radial deformation of the inner guard tooth, thereby improving the reliability of the motor operation.

[0050] A skeleton groove is formed between the outer wall 1, the inner tooth guard 2 and the skeleton bridge 3, and a groove insulating layer 4 is arranged in the skeleton groove.

[0051] Preferably, step grooves 5 are formed on both sides of the skeleton bridge 3 in the circumferential direction, and the groove insulating layer 4 is arranged in the step groove 5. Preferably, the step height of the step groove 5 is a, wherein a is greater than or equal to the thickness of the groove insulating layer 4.

[0052] By reasonably adding a protruding step structure of the insulating skeleton slot contour on the basis of the existing insulating skeleton slot, a step difference of height a is designed between the skeleton slot and the stator core slot contour at the far end of the slot insulation end face where the stator axial skeleton core end face matches, ensuring that the extrusion force of the winding wire package at the stator axial skeleton core end face matches is fully applied to the skeleton, protecting the end of the slot insulation film, effectively reducing the risk of the slot insulation layer 4 being broken due to winding extrusion, and improving the reliability of the motor.

[0053] Preferably, there is an axial spacing d between the slot insulation layer 4 and the side wall of the step slot 5. Preferably, d=(axial height deviation of the stator core 8+axial height deviation of the slot insulation layer 4+axial height difference of the stator core 8 before and after winding) / 2+axial thickness deviation of the skeleton bridge 3.

[0054] Since the height of the stator core 8 fluctuates and the winding extrusion pressure will force the height of the stator core 8 to decrease after the stator is wound, in order to ensure that the slot insulation layer 4 does not have axial interference with the skeleton bridge 3 of the insulation skeleton under extreme conditions, resulting in curling failure or collapse of the slot insulation layer 4, the present invention designs a buffer distance d between the side wall of the step groove 5 and the slot insulation end face along the axial direction, thereby further reducing the risk of the slot insulation layer 4 being crushed by the winding extrusion pressure and improving the reliability of the motor.

[0055] Preferably, an embedding groove 6 for placing the incoming wire head 7 is provided on the inner side wall of the outer wall 1. The incoming wire head of the first turn coil of the existing insulating skeleton winding does not avoid the subsequent coils and will be subjected to a large extrusion force, and there is a risk of excessive deformation or even breakage of the enameled wire. By providing the embedding groove 6 on the inner side wall of the outer wall 1, when the first turn incoming wire head 7 of the winding is introduced, the first turn incoming wire head 7 can be set in the embedding groove 6, and the extrusion of the subsequent coils is reduced by the embedding groove 6, which greatly reduces the extrusion force on the first turn incoming wire head 7 of the winding, reduces the hidden danger of excessive deformation or even breakage of the first turn incoming wire head 7 of the winding due to excessive extrusion, and improves the reliability of the motor.

[0056] Preferably, the depth e of the embedded groove 6 is greater than or equal to the wire diameter of the incoming wire end 7, so that the incoming wire end 7 can be completely embedded in the embedded groove 6 and no longer be subjected to the squeezing force of the subsequent coil, further forming effective protection for the incoming wire end 7 and improving the reliability of the motor.

[0057] Preferably, the outer side wall of the outer wall 1 is provided with convex ribs at positions corresponding to the embedding grooves 6. By providing the convex ribs, the structural strength of the outer wall 1 at the positions where the embedding grooves 6 are provided can be increased.

[0058] Preferably, the incoming wire ends 7 include N enameled wires wound in parallel, and the width of the embedding slot 6 is greater than or equal to N times the diameter of the enameled wires, where N is an integer greater than 1. If the winding is a plurality of enameled wires wound in parallel, it is necessary to ensure that the width of the embedding slot 6 is at least not less than several times the diameter of the winding wires wound in parallel, so as to ensure that all the first turns of the incoming wire ends 7 of the winding can be effectively avoided.

[0059] According to an embodiment of the present invention, the stator assembly includes a stator core 8 and an insulating frame arranged on the stator core 8, and the insulating frame is the insulating frame mentioned above.

[0060] According to an embodiment of the present invention, the motor includes a stator core 8 and an insulating frame arranged on the stator core 8, and the insulating frame is the insulating frame mentioned above.

[0061] It is easy for those skilled in the art to understand that, under the premise of no conflict, the above-mentioned advantageous methods can be freely combined and superimposed.

[0062] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention shall be included in the protection scope of the present invention. The above are only preferred embodiments of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and variations can be made without departing from the technical principles of the present invention, and these improvements and variations should also be regarded as the protection scope of the present invention.

Claims

1. An insulating skeleton, characterized in that: The invention comprises an outer wall (1), an inner tooth (2), and a skeleton bridge (3) connecting the outer wall (1) and the inner tooth (2); the axial height of the inner tooth (2) is lower than the axial height of the outer wall (1); an embedding groove (6) for accommodating an incoming wire end (7) is provided on the inner side wall of the outer wall (1); the depth of the embedding groove (6) is greater than or equal to the wire diameter of the incoming wire end (7) and less than the wall thickness of the outer wall (1).

2. The insulating frame according to claim 1, characterized in that: The height h of the inner guard teeth (2) satisfies h=b+c, ​​wherein b is the maximum height of the winding wire package in contact with the inner guard teeth (2), and c is the axial thickness of the skeleton bridge (3).

3. The insulating frame according to claim 1, characterized in that: The height h of the inner guard tooth (2) satisfies h=b+c+x, wherein b is the maximum height of the winding wire package in contact with the inner guard tooth (2), c is the axial thickness of the skeleton bridge (3), and x is the maximum rebound height of the winding end in contact with the inner guard tooth (2).

4. The insulating frame according to claim 1, characterized in that: The axial height of the inner tooth (2) is 60% to 70% of the axial height of the outer wall (1).

5. The insulating skeleton according to any one of claims 1 to 4, characterized in that: A skeleton groove is formed between the outer wall (1), the inner tooth guard (2) and the skeleton bridge (3), and a groove insulating layer (4) is provided in the skeleton groove.

6. The insulating frame according to claim 5, characterized in that: Step grooves (5) are formed on both sides of the skeleton bridge (3) in the circumferential direction, and the groove insulation layer (4) is arranged in the step groove (5).

7. The insulating frame according to claim 6, characterized in that: The step height of the step groove (5) is a, wherein a is greater than or equal to the thickness of the groove insulation layer (4).

8. The insulating frame according to claim 6, characterized in that: There is an axial distance d between the groove insulating layer (4) and the side wall of the step groove (5).

9. The insulating frame according to claim 8, characterized in that: d=(the upper deviation of the axial height of the stator core (8)+the upper deviation of the axial height of the slot insulation layer (4)+the axial height difference of the stator core (8) before and after winding) / 2+the upper deviation of the axial thickness of the skeleton bridge (3).

10. The insulating frame according to claim 1, characterized in that: The outer side wall of the outer wall (1) is provided with a convex rib at a position corresponding to the embedding groove (6).

11. The insulating frame according to claim 1, characterized in that: The incoming wire end (7) comprises N enameled wires wound in parallel, and the width of the embedding groove (6) is greater than or equal to N times the diameter of the enameled wire.

12. A stator assembly, comprising a stator core (8) and an insulating frame arranged on the stator core (8), characterized in that: The insulating skeleton is the insulating skeleton according to any one of claims 1 to 11.

13. A motor, comprising a stator core (8) and an insulating frame arranged on the stator core (8), characterized in that: The insulating skeleton is the insulating skeleton according to any one of claims 1 to 11.

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