A stator connection and positioning structure

Abstract

A stator connection and positioning structure, belonging to the field of elastohydrodynamic stator technology, includes a motor housing, a stator core, and a bearing bracket. The stator core is composed of segmented stator core assemblies arranged in a ring. Adjacent stator core assemblies are connected by mortise and tenon joints. Each stator core assembly has a mortise at one end and a tenon at the other end that corresponds to the mortise. The tenon is fitted into the mortise of an adjacent stator core assembly. The stator core of this invention is first formed by overlapping multiple stator segmented laminations at symmetrical snap-fit ​​points to create a 120° segmented structure. Then, three stator core segments are stamped together using tooling to form a single integral stator core. The segments of the stamped stator core are tightly fitted and cannot slide against each other.

Description

Technical Field

[0001] This invention belongs to the field of elastohydrodynamic stator technology, and specifically relates to a stator connection and positioning structure. Background Technology

[0002] A centrifugal fan in a vacuum cleaner uses a motor rotor to drive a centrifugal impeller to rotate at high speed, creating negative air pressure inside a sealed casing, which in turn sucks dust and other debris into a dust collection bag.

[0003] The stator mechanism is a crucial component of the centrifugal fan in a vacuum cleaner. Existing stator core connection structures are generally either loose-fit press-fit or welded connections. In the former, the three segments of the stator core can slide between each other, relying on the winding frame and winding wire for axial dimensional constraints, which increases the difficulty of winding. On the other hand, welded connections compromise the insulation of the stator core, increase eddy current losses, and add costs associated with the welding process. Summary of the Invention

[0004] In view of the shortcomings of the prior art, the purpose of the present invention is to provide a stator connection and positioning structure.

[0005] The present invention adopts the following technical solution.

[0006] A stator connection and positioning structure includes a motor housing, a stator core, and a bearing bracket. The stator core is composed of segmented stator core assemblies arranged in a ring. Adjacent stator core assemblies are connected by mortise and tenon joints. One end of each stator core assembly is provided with a mortise, and the other end is provided with a tenon adapted to the mortise. The tenon is embedded in the mortise of an adjacent stator core assembly.

[0007] The motor housing is a hollow cylinder with a positioning pin groove on the upper part of its inner wall; the inner wall of the motor housing is evenly distributed with first threaded holes and first pins at equal angles.

[0008] The stator core assembly includes an arc-shaped frame, a stator positioning frame, and an inner circular frame; the side of the arc-shaped frame is arc-shaped with a central angle of 120°; the upper end of the stator positioning frame is fixedly installed on the inner wall of the arc-shaped frame, and the lower end is fixedly installed in the middle of the inner circular frame; the side of the inner circular frame is arc-shaped, and the inner circular frame and the arc-shaped frame are coaxially arranged; a winding groove is formed between adjacent stator positioning frames, and a gap is provided between adjacent inner circular frames.

[0009] A stator positioning component is provided in the middle of the outer wall of the arc-shaped frame; the stator positioning component includes axially arranged positioning through holes and pin holes; the bearing frame is an integral claw structure, including a second bearing chamber and three radially equidistant curved claws arranged at the outer edge of the second bearing chamber; the free end of the curved claw is provided with a second threaded hole and a second pin; the first pin and the second pin are respectively inserted into the pin holes at both ends of the stator core assembly; bolts are passed through the second threaded hole, the positioning through hole, and the first threaded hole;

[0010] The stator core assembly is formed by stacking and riveting stator core assembly laminations; the stator core assembly laminations are sheet-shaped, and their shape is the same as the side shape of the stator core assembly; the stator core assembly laminations include arc-shaped pieces, stator positioning pieces, and inner circular pieces; the left middle part of the arc-shaped piece, the right middle part of the arc-shaped piece, and the middle part of the stator positioning piece are all provided with riveting points.

[0011] The stator mechanism also includes a winding frame; the winding frames are respectively disposed on both sides of the stator core assembly, and the winding frames on both sides of the stator core assembly cover the entire surface of the stator positioning frame and the upper surface of the inner circular frame; the inner wall of the inner circular frame is exposed; the winding frame is provided with a protruding eave; the protruding eave extends axially along the inner circular frame.

[0012] The stator core of this invention is first formed by stacking multiple stator segmented laminations together at symmetrical snap points to form a 120° stator core segmented structure. Then, the three stator core segments are stamped together using tooling to form an integral stator core. The segments of the stamped stator core are tightly fitted together and cannot slide against each other. The stator core and the motor housing adopt a pin positioning structure, which is convenient for installation and less affected by dimensional and geometric tolerances. Attached Figure Description

[0013] Figure 1 This is an assembly drawing of the stator mechanism;

[0014] Figure 2 This is a top view of the stator core;

[0015] Figure 3 It is a 3D diagram of the stator core;

[0016] Figure 4 This is a 3D view of the stator core assembly;

[0017] Figure 5 This is a top view of the stator core assembly laminations;

[0018] Figure 6 It is a three-dimensional drawing of the bearing bracket;

[0019] Figure 7 This is another 3D view of the bearing bracket;

[0020] Figure 8 It is a 3D diagram of a winding frame;

[0021] Figure 9 It is a 3D view of the motor housing;

[0022] In the diagram: stator mechanism 500, motor housing 501, positioning pin groove 502, stator core 503, first threaded hole 504, first pin 505, stator core assembly 506, arc frame 507, stator positioning frame 508, inner round frame 509, winding groove 510, positioning through hole 511, pin hole 512, stator core assembly lamination 513, arc piece 514, stator positioning piece 515, inner round piece 516, riveting point 517, winding frame 518, bearing frame 519, second bearing chamber 520, bent claw 521, second threaded hole 522, second pin 523, eaves 524, mortise 525, tenon 526. Detailed Implementation

[0023] The present invention will now be described in further detail with reference to the accompanying drawings.

[0024] A stator connection and positioning structure includes a motor housing 501, a stator core 503, a winding frame 518, and a bearing frame 519.

[0025] The motor housing 501 is a hollow cylinder, and a positioning pin groove 502 is provided on the upper part of its inner wall.

[0026] The inner wall of the motor housing 501 is provided with first threaded holes 504 and first pins 505 evenly distributed at equal angles. Preferably, there are 3 pairs of first threaded holes 504 and first pins 505, and the angle between adjacent first threaded holes 504 is 60°.

[0027] The stator core 503 is composed of three segmented stator core assemblies 506 arranged in a ring; adjacent stator core assemblies 506 are connected by tenon and mortise joints with interference fit.

[0028] The stator core assembly 506 has a mortise 525 at one end and a tenon 526 at the other end that corresponds to the mortise 525; the tenon 526 is fitted into the mortise 525 of an adjacent stator core assembly 506. Preferably, the tenon 526 and the mortise 525 are trapezoidal in shape. Alternatively, the tenon 526 and the mortise 525 are triangular or arc-shaped, but conventional mortise and tenon structures can also be used.

[0029] Traditional stator core connection structures are generally loose-fit press-fit or welded connections. In the former, the three segments of the stator core can slide between each other, and the axial dimensions are constrained by the winding frame and the winding wire. Sliding and misalignment will pull on the enameled wire, and repeated folding will easily damage the enameled wire, increasing the difficulty of winding. On the other hand, welding the stator core connection will destroy the insulation between the upper and lower layers of the stator core, increase eddy current losses and the cost due to the welding process.

[0030] The stator core assembly 506 of the present invention is first formed by multiple stator segmented laminations stacked together at symmetrical snap points to form a 120° stator core segmented structure. Then, the three stator core segments are stamped to form an integral stator core. The segments of the stamped stator core are tightly fitted together and cannot slide against each other.

[0031] The stator core assembly 506 includes an arc-shaped frame 507, a stator positioning frame 508, and an inner circular frame 509. The side of the arc-shaped frame 507 is arc-shaped with a central angle of 120°. The upper end of the stator positioning frame 508 is fixedly installed on the inner wall of the arc-shaped frame 507, and the lower end is fixedly installed in the middle of the inner circular frame 509. The side of the inner circular frame 509 is arc-shaped, and the inner circular frame 509 and the arc-shaped frame 507 are coaxially arranged. A winding groove 510 is formed between adjacent stator positioning frames 508, and adjacent inner circular frames 509 are spaced apart.

[0032] It is worth noting that the stator mechanism 500 can adopt a three-slot, three-phase structure, in which case the upper end of the stator positioning frame 508 is fixedly installed in the middle of the inner wall of the arc-shaped frame 507; it can also adopt a six-slot, three-phase structure. Any conventional changes in the number or position of components should be considered as equivalent substitutions of this solution, and thus fall within the protection scope of this application.

[0033] This technical solution involves tenoning and pressing together the segmented stator core assembly 506 to form a segmented stator core. The resulting integral stator core is then wound using a winding frame. The completed stator winding is connected to the bearing bracket via a positioning structure and the motor housing. This solution yields the following beneficial effects:

[0034] 1. Reduce welding processes, lower eddy current losses, and improve motor efficiency;

[0035] 2. Reduce the difficulty and cost of mold development;

[0036] 3. Ensure that the motor housing, bearing bracket and stator core are concentric to reduce unbalanced electromagnetic forces and reduce vibration;

[0037] 4. Convenient winding: The stator core can be wound and then assembled.

[0038] A stator positioning component is provided in the middle of the outer wall of the arc-shaped frame 507. Preferably, the stator positioning component includes a positioning through hole 511 and a pin hole 512, both arranged axially.

[0039] The bearing housing 519 is an integral claw structure, including a second bearing chamber 520 and three curved claws 521 arranged radially at equal angles on the outer edge of the second bearing chamber 520; the free end of the curved claw 521 is provided with a second threaded hole 522 and a second pin 523.

[0040] During installation, the first pin 505 on the motor housing 501 and the second pin 523 on the bearing bracket 519 are first inserted into the pin holes 512 at both ends of the stator core assembly 506, thereby initially positioning the motor housing 501, the stator core assembly 506, and the bearing bracket 519. Then, bolts are used through the second threaded hole 522 on the bearing bracket 519, the positioning through hole 511 of the stator core assembly 506, and the first threaded hole 504 of the motor housing 501 to clamp the stator core assembly 506 between the motor housing 501 and the bearing bracket 519. Preferably, the positioning through hole 511 can be a smooth-walled round hole or a semi-circular hole, and the inner walls of both the first threaded hole 504 and the second threaded hole 522 are threaded. Alternatively, the positioning through hole 511 can be a smooth-walled round hole or a semi-circular hole, and the inner walls of both the first threaded hole 504 and the second threaded hole 522 are smooth. The bolt is secured with a nut after passing through the second threaded hole 522, the positioning through hole 511, and the first threaded hole 504.

[0041] Traditional pin-mounted positioning structures suffer from problems during rotor installation, such as the stator being lifted by the magnets and damaging the pins, or the stator failing to fit due to dimensional or geometric tolerances. This new design utilizes a pin-mounted positioning structure between the stator core and the motor housing, facilitating installation and minimizing the impact of dimensional and geometric tolerances.

[0042] Currently, in the installation of vacuum cleaner motors on the market, the bearing bracket is fastened to the motor housing, causing the stator core to be unloaded and suspended, which is prone to vibration. In the stator core installation of this invention, the bearing bracket bears the force on the stator core and is circumferentially positioned by pins, then secured with bolts, ensuring that the stator core has restraint in all directions within the machine body, thus reducing vibration.

[0043] The stator core of commercially available vacuum cleaner motors is not installed concentrically, causing an unbalanced electromagnetic force during rotation, resulting in vibration, increased wear, and reduced bearing life. The stator core installation of this invention adds three cylindrical pins to both the motor housing and the bearing bracket, ensuring concentricity between the stator core and the housing, and between the stator core and the bearing bracket. This concentricity of the motor housing, bearing bracket, and stator core reduces unbalanced electromagnetic forces and lowers vibration.

[0044] Preferably, after the mechanical fixing of the motor housing 501, stator core assembly 506, and bearing bracket 519 is completed, glue can be added at the connection between the motor housing 501 and the stator core assembly 506, and at the connection between the stator core assembly 506 and the bearing bracket 519 to tighten the position, thereby further ensuring the structural strength of the motor.

[0045] The stator core assembly is formed by stacking and riveting stator core assembly laminations 513. The stator core assembly laminations 513 are sheet-like, and their shape is the same as the side shape of the stator core assembly 506. Different numbers of stator core assembly laminations 513 can be selected and stacked and riveted as needed to form a stator core assembly 506 of the required thickness. The stator core assembly laminations 513 include arc-shaped pieces 514, stator positioning pieces 515, and inner circular pieces 516; rivet points 517 are provided at the middle left side of the arc-shaped piece 514, the middle right side of the arc-shaped piece, and the middle of the stator positioning piece 515.

[0046] Preferably, the stator mechanism 500 further includes a winding frame 518; the winding frames 518 are respectively disposed on both sides of the stator core assembly 506, and the winding frames 518 on both sides of the stator core assembly 506 cover the entire surface of the stator positioning frame 508 and the upper surface of the inner circular frame 509. The inner wall of the inner circular frame 509 is exposed. The winding frame 518 is provided with a protruding eave 524; the protruding eave 524 extends axially along the inner circular frame 509.

[0047] After the stator core is formed, winding frames need to be added to the top and bottom. The shape of the winding frames is set according to the shape of the stator core, and it consists of six parts in two three-lobed sections. During installation, the winding frame with terminals is attached to the top, and the other winding frame is attached to the bottom. After installation, the enameled wire is wound to form the stator winding. The functions of the winding frames are: 1. To prevent the enameled wire from directly contacting the stator core, providing insulation protection; 2. To constrain the size of the enameled wire in the winding, preventing the enameled wire from loosening and entering the inner circle to contact the rotor magnets; 3. To ensure the positioning of the three-phase wires of the winding and reduce vibration.

[0048] Existing stator core connection structures are generally loose-fit press-fit or welded connections. In the former, the three segments of the stator core can slide between each other, and the axial dimensions are constrained by the winding frame and the winding wire, which increases the difficulty of winding. On the other hand, the welded connection destroys the insulation of the stator core, increases eddy current loss and the cost due to the welding process.

[0049] The stator core of this invention is first formed by overlapping multiple stator laminations at symmetrical snap-fit ​​points to create a 120° stator core segment structure. Then, using tooling, three stator core segments are stamped to form a single integral stator core. The stamped stator core segments are tightly fitted and cannot slide against each other. The stator core and motor housing use a pin-positioning structure, which facilitates installation and is less affected by dimensional and geometric tolerances. This invention solves the problems of reduced efficiency due to welding damaging the stator core's insulation and relative movement caused by loose-fitting press-fitting. It also solves the problems of stator core eccentricity and vibration.

[0050] It is understood that those skilled in the art can make equivalent substitutions or modifications to the technical solution and inventive concept of the present invention, and all such substitutions or modifications should fall within the protection scope of the appended claims.

Claims

1. A stator connection and positioning structure, comprising a motor housing (501), a stator core (503), and a bearing bracket (519), characterized in that, The stator core (503) is composed of segmented stator core assemblies (506) arranged in a ring; adjacent stator core assemblies (506) are connected by mortise and tenon joints; one end of the stator core assembly (506) is provided with a mortise (525), and the other end is provided with a tenon (526) adapted to the mortise (525); the tenon (526) is embedded in the mortise (525) of the adjacent stator core assembly (506); the tenon (526) and the mortise (525) are trapezoidal in shape; the stator core assembly (506) is first formed by multiple stator segmented stamping pieces overlapping each other with symmetrical fastening points to form a 120° stator core segmented structure, and then the three stator core segments are stamped to form an integral stator core, and the segments of the stamped stator core are tightly fitted and cannot slide against each other; The motor housing (501) is a hollow cylinder, and a positioning pin groove (502) is provided on the upper part of its inner wall; the inner wall of the motor housing (501) is evenly distributed with first threaded holes (504) and first pins (505) at equal angles. The stator core assembly (506) includes an arc frame (507), a stator positioning frame (508), and an inner circular frame (509); the side of the arc frame (507) is arc-shaped with a central angle of 120°; the upper end of the stator positioning frame (508) is fixedly installed on the inner wall of the arc frame (507), and the lower end is fixedly installed in the middle of the inner circular frame (509); the side of the inner circular frame (509) is arc-shaped, and the inner circular frame (509) and the arc frame (507) are coaxially arranged; a winding groove (510) is formed between adjacent stator positioning frames (508), and an interval is provided between adjacent inner circular frames (509); A stator positioning component is provided in the middle of the outer wall of the arc-shaped frame (507); the stator positioning component includes a positioning through hole (511) and a pin hole (512) arranged axially; the bearing frame (519) is an integral claw structure, including a second bearing chamber (520) and three curved claws (521) arranged radially at equal angles on the outer edge of the second bearing chamber (520); the free end of the curved claw (521) is provided with a second threaded hole (522) and a second pin (523); the first pin (505) and the second pin (523) are respectively inserted into the two ends of the pin hole (512) of the stator core assembly (506); bolts are passed through the second threaded hole (522), the positioning through hole (511), and the first threaded hole (504).

2. The stator connection and positioning structure as described in claim 1, characterized in that, The stator core assembly (506) is formed by stacking and riveting stator core assembly laminations (513); the stator core assembly laminations (513) are in the shape of sheets, and their shape is the same as the side shape of the stator core assembly (506); the stator core assembly laminations (513) include arc-shaped pieces (514), stator positioning pieces (515), and inner circular pieces (516); the arc-shaped pieces (514) are provided with riveting points (517) in the middle left side, the middle right side, and the middle of the stator positioning pieces (515).

3. The stator connection and positioning structure as described in claim 1, characterized in that, The stator mechanism (500) also includes a winding frame (518); the winding frame (518) is disposed on both sides of the stator core assembly (506), and the winding frames (518) on both sides of the stator core assembly (506) cover the entire surface of the stator positioning frame (508) and the upper surface of the inner circular frame (509); the inner wall of the inner circular frame (509) is exposed; the winding frame (518) is provided with a protruding eave (524); the protruding eave (524) extends axially along the inner circular frame (509).

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