Pump for a domestic appliance for wading operations

Abstract

A pump for a wading implement, the pump having an electric motor comprising: a rotor comprising a ferrite body having at least four magnetic poles, wherein the ferrite body has a transverse-circumferential magnetization; and a stator comprising a pole chain made from a stack of a plurality of straight transformer sheets and rounded into a circular configuration by bending the stacked transformer sheets, wherein the pole chain has a plurality of pole sections each comprising pole teeth; and a plurality of winding cores connected to respective pole teeth for accommodating coils of a three-phase winding comprising conductive wires; wherein the conductive wires of each phase of the three-phase winding are routed spatially separate from each other and without mutual contact between and along adjacent winding cores around the pole chain at axial end faces of the pole chain; and wherein the conductive wires are supported and guided such that their position relative to the pole chain is substantially maintained when the pole chain is rounded from its straight line configuration to its circular configuration.

Description

Technical Field

[0001] This invention relates to the field of water-conducting appliances such as dishwashers and washing machines, and more particularly to the field of water-conducting household appliances. The invention relates to a pump for such water-conducting appliances. Washing machines and dishwashers are machines that clean, rinse, and dry clothes or dishes by chemical, mechanical, thermal, and electrical means, respectively. The invention also relates to a pump including an electric motor and a method of manufacturing the same. Background Technology

[0002] Pumps typically move or transport fluids (liquids or gases) by transferring mechanical energy to the pumped fluid, particularly by creating a pressure differential between the pump's inlet and outlet. This mechanical energy is derived from an electric motor that receives electrical energy. Pumps and associated motors in water-operated household appliances such as dishwashers are also affected by high-temperature fluctuations in the transported medium. To improve cost efficiency, energy efficiency, and space efficiency, and to conserve resources, heating systems integrated into the pump casing have proven advantageous. Water circulates in its respective pump circuit, with temperatures mostly ranging from +5°C to approximately +85°C (maximum +100°C), a typical volumetric flow rate of 45 liters per minute, and a typical pressure differential between the pump's inlet and outlet of approximately 300 millibars (mbar). According to existing technology, electric motors with an internal wet rotor design in the form of centrifugal pumps are preferred for this purpose.

[0003] This type of motor is preferably constructed as a brushless DC motor (BLDC motor). The motor is manufactured by winding insulated conductors (preferably enameled copper wire) onto the winding cores of each phase (e.g., U, V, W phases). When one coil is finished winding on one winding core, the insulated conductor is routed to the next winding core to wind the next coil of that phase. After all the coils in a phase are wound, the insulated conductor is led out to the contact points. All other phases are manufactured in this operational sequence or in parallel.

[0004] The stator core can be formed from an initial straight pole chain comprising multiple stacked transformer laminations having a straight or linear configuration and including multiple pole teeth, with adjacent pole teeth connected to each other by thin bends. By bending the bends and connecting the corresponding pole teeth at the ends of the pole chain, the stacked core is rounded to its final circular structure. Individual coils (windings) of the pole chain can be wound on individual pole teeth in a linear or straight state, or in a circular state. Winding the coils in a straight state is advantageous because the distance between individual pole teeth is greater, and more space is available for the wire-laying tool, making the laying of the wires for each (three) phase and the winding of the coils easier and faster. If the pole chain is rounded after winding the coils, the width of the slots between adjacent pole teeth can be advantageously designed (e.g., smaller), resulting in lower cogging torque of the motor because no space is needed to guide the wire-laying tool through the slots between adjacent pole teeth.

[0005] The coil is typically made of enameled copper wire wound together. Enameled aluminum wire can be an option, but it is considered more difficult to handle and requires a different stator design. For round copper wire (uninsulated), the conductivity of the bare conductor is approximately 58.5 m / Ω·mm. 2 Aluminum has a relatively low electrical conductivity, approximately 35.85 m / Ω·mm. 2 Therefore, when using enameled aluminum wire instead of copper wire, the cross-sectional area of ​​the wire must be increased according to the ratio of their respective conductivities to avoid increased power loss and to ensure that the motor has similar power and temperature characteristics. In this case, the cross-sectional area of ​​the enameled aluminum wire should be increased by approximately 3 / 2 times compared to copper wire. Consequently, to accommodate the increased wire volume, the iron laminations (core) and all mechanical components of the motor must also be increased in size.

[0006] Furthermore, compared to copper conductors, the processability of enameled aluminum conductors is limited due to the elastic limit and tensile strength of aluminum conductors, as can be seen from Table 1, which shows some physical properties of typical copper and aluminum materials (E-CU and E-Al F7) used for enameled wires. Additionally, the thermal management of the motor is affected in this case, such as heat dissipation.

[0007]

[0008]

[0009] Table 1

[0010] The insulation of electrical conductors (such as round copper or aluminum wires) is typically a coating or covering (such as varnish or enamel varnish, like polyurethane, polyesterimide, or polyimide) to resist voltage and prevent short circuits between adjacent wires. During the winding process, the coating is subjected to considerable stress, especially in the bending and stretching areas of the wire. Furthermore, manufacturers of enameled wire state that the insulation coating of such wires initially has up to 40 defects per 30 running meters. These defects, whether present from the beginning or introduced by stress during wiring, are the most common source of motor failure due to electrical short circuits. The voltage difference between adjacent wire layers within a coil is typically only a few volts. However, much higher voltages can occur between different phases of the motor, making any defects in the wire coating more likely to cause spark discharges and short circuits. As mentioned above, due to different material properties, the insulation coating of aluminum wires is more susceptible to such defects than that of copper wires. The cost of copper and aluminum wires varies significantly over time, making the use of aluminum wires in such motor windings economically viable. Summary of the Invention

[0011] The object of this invention is to improve the pump described above for use in water-related operations. Another object is to improve the electric motor of the pump and to provide a design for the electric motor that can selectively use aluminum or copper wire as stator windings while ensuring a low failure rate and high and reliable performance and efficiency.

[0012] In a first aspect, the present invention provides a pump for water-operated appliances, particularly for household appliances such as dishwashers or washing machines, having an electric motor comprising: a rotor comprising a ferrite body having at least four magnetic poles, wherein the ferrite body is transversely-circumferentially magnetized; a stator comprising: a pole chain made of a stack of a plurality of straight transformer plates and rounded into a circular configuration by bending the stacked transformer plates, wherein the pole chain has a plurality of pole portions, each pole portion comprising pole teeth; and a plurality of winding cores attached to corresponding pole teeth for accommodating coils of a three-phase winding comprising conductors; wherein the conductors of each phase of the three-phase winding are spatially separated from each other and do not contact each other between adjacent winding cores around the pole chain and along the adjacent winding cores at the axial end faces of the pole chain; and wherein the conductors are supported and guided such that their position relative to the pole chain is substantially maintained as the pole chain is rounded from its straight configuration to its circular configuration.

[0013] The ferrite body preferably has transverse-circumferential magnetization, which helps ensure the desired arcuate arrangement of the iron oxide component in the ferrite body material. Furthermore, the orientation of the magnetic poles preferably features that each individual magnetic pole on the outer peripheral surface of the ferrite body is circumferentially aligned with a catch portion disposed on the outer peripheral surface of the rotor core element supporting the ferrite body. Accordingly, the cracking tendency of the ferrite body can be reduced, and the magnetic flux within the ferrite body can be improved and enhanced.

[0014] The ferrite matrix may contain at least one mechanically stabilizing additive, such as manganese, cobalt, or lanthanum. This allows for the compensation of internal stresses generated during sintering.

[0015] The conductors of the three-phase winding can be routed in three axially separated wiring planes, which have different axial horizontal positions along the axis of the circular pole chain, wherein each conductor (1, 2, 3) is routed substantially in the corresponding one of the wiring planes. Alternatively, the conductors can be routed in radially separated wiring surfaces (cylindrical surfaces).

[0016] Each winding core may optionally further include a support device configured to support and guide the corresponding wire to a corresponding one in a separate wiring plane as the coil on the winding core is allowed to enter or leave.

[0017] Additionally or alternatively, each winding core may also include a support separator formed as a recess in the coil space boundary wall of the winding core, the recess having a defined depth such that the bottom line of the recess is located in an axially horizontal position in one of the wiring planes. Optionally, at least one support separator may further include a winding asymmetry device.

[0018] Additionally or alternatively, the winding core may further include a winding displacement device located on the inner wall of the coil space of the winding core.

[0019] In some embodiments, each winding core may further include a support pin configured to support a conductor and guide the conductor from one winding core along a spatially separated wiring path to an adjacent winding core. In some embodiments, the support pin may be configured to support a conductor in an axially separated wiring plane and guide the conductor from one winding core to an adjacent winding core. The support pin may optionally include a shoulder or recess to support the conductor and prevent axial movement of the conductor. Additionally or alternatively, the support pin may have a forked configuration to individually support the conductor and prevent axial movement of the conductor.

[0020] In some embodiments, the support pin can be positioned such that the conductor is guided along a path from one winding core to an adjacent winding core, the path passing near or intersecting the pivot axis, the adjacent pole teeth pivoting around the pivot axis as the pole chain is rounded to its circular configuration.

[0021] In some embodiments, the transverse sidewall of the coil space of the winding core facing the stator circumferential direction has a larger tilt angle (γ) than the tilt angle (α) of the narrow side of the coil space facing the stator axial direction, wherein the difference (β) between angles (α) and (γ) is preferably set to 5° to 25°, more preferably to 10° to 15°.

[0022] The conductors for the three-phase windings are preferably enameled wires made of aluminum or aluminum alloy.

[0023] Further advantages and preferred embodiments of the invention will now be described in conjunction with the accompanying drawings listed below. In the following description, the expressions “left,” “right,” “lower,” and “upper” refer to aligned figures such that the reference numerals and symbols used are readable in the normal orientation. Attached Figure Description

[0024] Figure 1 This is a perspective view of the stator of the electric motor according to the present invention in its circular structure;

[0025] Figure 2 yes Figure 1 A perspective view of the stator's direct pole chain after the coil is wound and before the pole chain is rounded into a circular structure;

[0026] Figure 3 yes Figure 1 and Figure 2 A perspective view of the direct pole chain of the stator, carrying the winding core before the winding operation;

[0027] Figure 4 yes Figure 3 An enlarged view of the marked section shows details of the winding core;

[0028] Figure 5 This is a table showing the horizontal positions of the support device divider according to the present invention;

[0029] Figure 6 This is an enlarged view of the connecting part, which connects the ends of the polar chains to each other after the polar chains are rounded into a circular structure.

[0030] Figure 7 It is an enlarged view showing the workpiece pickup tool engaging with the pickup groove of the winding core;

[0031] Figure 8 It is a circuit diagram showing the interconnection of the coils of the three phases of the electric motor;

[0032] Figure 9 This is a partial cross-sectional view showing the winding core according to the present invention;

[0033] Figure 10 This is a schematic cross-sectional view of the stator according to the present invention;

[0034] Figure 11 This is a perspective view of a portion of the stator according to the present invention;

[0035] Figure 12 It is a perspective view showing the non-contact wiring between the stator coils;

[0036] Figure 13a This is a perspective view of the stacked iron core of the straight pole chain according to the present invention;

[0037] Figure 13b This is a plan view of a single iron sheet of a straight electrode chain according to the present invention;

[0038] Figure 13c yes Figure 13b An enlarged view of the end of the iron sheet;

[0039] Figure 14 This is an enlarged view of a portion of the winding core according to the invention; and

[0040] Figure 15 It is a perspective view of a single-winding core mounted on a direct-pole chain core.

[0041] Figure 16 This is a perspective view of the electric motor according to the present invention;

[0042] Figure 17 yes Figure 2 A cross-sectional view of the electric motor;

[0043] Figure 18 yes Figure 2 A cross-sectional view of the rotor and stator of the electric motor;

[0044] Figure 19 This is a top view of the ferrite body of the rotor, showing the magnetization direction of the magnetic poles of the ferrite body;

[0045] Figure 20 This is a perspective view of the pump housing components;

[0046] Figure 21 It is installed in Figure 20 A perspective view of the motor cover of the pump housing on the pump housing component. Detailed Implementation

[0047] Reference Figure 16 and 17In a first embodiment, the present invention provides a pump P comprising a housing and an electric motor. The housing has an inlet 40 and an outlet 50 for pumping a liquid. The electric motor has an inner rotor 10 and an outer stator 20. The rotor 10 is a permanent magnet rotor, and the stator 20 is preferably an electronically commutated three-phase stator, such that the electric motor is a brushless DC motor, commonly referred to as a BLDC motor. For example, such a motor can be used to drive circulation pumps in dishwashers, washing machines, or similar household appliances, or in industrial or commercial equipment.

[0048] Specifically, the present invention provides an electric motor comprising a rotor 10 and a stator 20. (Refer to...) Figure 1 and Figure 2 The stator 20 is designed as a pole chain 100, which is formed by a stack of magnet laminations (electric sheets) 120 111, which are usually iron sheets that initially have a straight or linear structure and form the magnetic core of the stator 20. Figure 13a The iron sheet stack 111 is shown. Figure 13b A single iron sheet 120 is shown. Depending on the number of poles in the stator pole chain 100, the iron sheet 120 includes multiple pole portions 130. In this embodiment, the pole chain includes nine poles; however, any other number of poles is feasible depending on the motor design. Each pole portion 130 is connected to an adjacent pole tooth 131 via a bend 132. When the straight pole chain 100 is rounded to its circular configuration to form a circular stator 20, the stacked bodies 111 of the iron sheets 120 bend at the corresponding bends 132, and the opposite ends of the pole chains are connected to each other at the engagement connection 110, which... Figure 13c As shown in detail. The engaging connection portion 110 of the iron sheet 120 has a recess inclined at 80° relative to the inner baseline of the rod portion, such that the clamp 110b can engage both ends of the pole chain and connect the two ends to each other, as shown in detail. Figure 6 As shown. Alternatively or additionally, the joint connection 110 can be secured by spot welding 110a, 110c or other connection processes. The preferred use of spot welding 110a, 110c with clamp 110b is advantageous in terms of stability and reliability.

[0049] Each pole portion 130 has pole teeth 131 that form an inner pole surface facing the rotor 10 and, after the pole chain is rounded into its circular configuration, an inner surface with an inner diameter of Di of the stator 20 is formed. The curved opposite sides of the pole portions 130 then form an outer surface of the stator 20 with a diameter of Do. The curved portion 132 between adjacent pole portions 130 includes a relatively thin sheet metal bridge and an angular recess facing the pole tooth side, the sheet metal bridge being able to bend without separating the adjacent pole portions 130, the angular recess having an angle θ of approximately θ = 360° / n, where n is the number of poles. In this embodiment, this results in θ = 40°, such that in the circular configuration of the pole chain 100, the side surfaces of the angular recesses are adjacent to each other with almost no gap between the side surfaces of adjacent pole portions 130. This provides good magnetic properties and ensures high power and low power loss of the motor without requiring additional devices for improving magnetic flux in the magnetic circuit, such as additional external magnetic ring elements. A schematic diagram of the circular polar chain 100 is shown below. Figure 10 As shown. The stator 20's pole chain design is advantageous compared to a standard rectangular sheet stack 400, such as... Figure 10 The thinner outer profile is shown because less iron material is needed in total to achieve motors with similar power characteristics. Furthermore, the inner diameter of the outer magnetic circuit can be made larger, thus providing more space to accommodate the winding coils. Figure 10 In the image, shaded area 114 depicts the extra space for the winding coil.

[0050] The stator 20's pole chain design significantly facilitates the winding operation because, compared to a conventional rectangular core design 400, the straight pole chain 100 has a much larger space between adjacent pole teeth 131, allowing the winding tool tip 113 to move more easily and quickly along the path 112 around each pole tooth 131, such as... Figure 2 As shown. This also requires less complex winding tools and machines, improving reliability and reducing the cost of manufacturing the stator 20. Furthermore, it allows for the use of larger diameter aluminum wires while maintaining the same number of turns per winding core compared to using copper wires. Therefore, the winding space between adjacent pole teeth 131 of the circular pole chain 100 can be utilized to a greater extent (higher fill factor), allowing for free selection between copper and aluminum wires without requiring a larger diameter stator 20. Consequently, there is no need to increase the size of the entire motor and related components.

[0051] like Figure 13aAs shown, the stator 20 of the present invention is manufactured by stacking multiple iron sheets 120 to form a straight stack 111 of pole chain 100. Subsequently, each pole tooth 131 of each pole portion 130 is provided with a respective winding core 200, which is preferably made of plastic or other insulating material. Preferably, the winding core 200 is injection molded around the pole tooth to provide enhanced heat transfer characteristics between the coil and the iron core and high stability of the final stator. It is also feasible to form the winding core 200 from two or more parts and then mount them to the pole tooth 131 by snap-fit ​​connection or any other connection method. Figure 3 The final pole chain is shown, comprising a core stack 111 and nine winding cores for the nine poles. Preferably, two winding cores 200 have corresponding retainers for contact terminals used to connect the stator 20 to an external drive circuit, such as a star point terminal holder 210 and a phase terminal holder 212, as shown. Figure 2 As shown. The star terminal retainer 210 and the phase terminal retainer 212 can be integrally formed with the winding core 200, or they can be separate elements, which can be attached to the body of the winding core 200, for example, by dovetail coupling. In this embodiment, the stator pole chain 100 includes nine pole teeth 131, which are associated with the three phases L1, L2, and L3 of the three-phase winding. In particular, a continuous series of pole teeth 131 are alternately associated with the three phases. In other words, Figure 3 The coils on pole teeth 1a, 2a, and 3a are associated with phase L1 and are wound with a single continuous wire 1. When wiring from pole tooth 1a to pole tooth 1b, the wire passes through the intermediate pole teeth of other phases, and so on. Therefore, the coils on pole teeth 2a, 2b, and 2c are wound with a single continuous wire 2, while the coils on pole teeth 3a, 3b, and 3c are wound with a single continuous wire 3. The straight-line construction of the pole chain 100 allows the use of two or three winding tools to perform the winding operations of the three phases L1, L2, and L3 at least partially simultaneously.

[0052] In this embodiment, a star or Y connection of the three phases L1, L2, and L3 is preferably used. However, other configurations (such as a delta connection) can also be used with minor adjustments. For example, when winding a single phase L1, wire 1 is connected to the star terminal 211 at the star terminal holder 210 and is routed to the first pole tooth 1c to wind coil 1c onto the corresponding winding core 200. Subsequently, wire 1 is routed through pole teeth 3b and 2b and reaches pole tooth 1b, where the second coil 1b of phase L1 is wound onto the corresponding winding core 200. After passing through pole teeth 3a and 2a, the wire is routed to pole tooth 1a to wind the last coil 1a of phase L1 and is finally routed to terminal L1 at phase terminal holder 212. Subsequently, or simultaneously, wires 2 and 3 are routed along the pole chain 100 from the star terminal 211 via corresponding pole teeth 2c, 2b, 2a and 3c, 3b, 3a to the phase terminals L2 and L3 in a manner similar to that of wire 1. The routing direction can also be reversed, such that the routing and laying of wires 1, 2, and 3 begins at the phase terminals L1, L2, L3 and ends at the star terminal 211. The preferred connection technique used at the terminals is insulation displacement, in which the contact blades cut through the wire coating and establish electrical contact when the wires are sandwiched between these blades. This allows for rapid and reliable contact at the terminals while minimizing the number of contact terminals, thus improving the reliability of the motor.

[0053] Finally, after all three phases have been wound, the straight pole chain 100 is rounded into its circular shape by bending the straight pole chain 100 at the bending portion 132 or the iron sheet 120 and connecting the opposite ends of the pole chain 100 at the joint connection portion 110.

[0054] Preferably, conductors 1, 2, and 3 are routed between coils 1a, 1b, 1c, 2a, 2b, 2c, 3a, 3b, and 3c such that the conductors do not come into contact with each other. In other words, conductors 1, 2, and 3 are routed without contact along the sequence of the respective winding cores 200, such that conductors 1, 2, and 3 are spatially separated from each other throughout the routing path. This prevents any short circuits between phases L1, L2, and L3 that could otherwise occur due to defects in the insulation coating of the enameled wires 1, 2, and 3 and high voltages occurring between these phases. In its simplest form, the spatial distance between conductors 1, 2, and 3 can be the air distance between the enameled wire surfaces, or it can be provided by an additional insulating device, preferably formed of the same material as the winding cores.

[0055] The non-contact wiring of conductors 1, 2, and 3 along pole chain 100 can be obtained in different ways, which are described below, and can be used individually or in combination.

[0056] The spatial distance between conductors 1, 2, and 3 can preferably be obtained by arranging the conductors substantially in separate planes with different axial positions relative to the axis of the circular stator 20. Alternatively or additionally, the conductors 1, 2, and 3 can also be routed substantially in separate cylindrical surfaces to achieve the spatial distance between them.

[0057] In a preferred embodiment of the stator 20, the conductors 1, 2, and 3 of the three phases U, V, and W are laid and wired according to the winding scheme, which will be described below in conjunction with... Figure 5 and 8 Let me explain. Using this scheme, conductor 1 emerges from star terminal 211 and enters the winding core 200 of coil 1c in a plane where axial position or horizontal position (level) "a" = 0, where 0 is the axial distance relative to an arbitrarily defined reference point on the motor axis. Then, conductor 1 leaves coil 1c in the same plane where axial position or horizontal position "b" = 0, and is routed within that plane to enter the next coil 1b, also at horizontal position "a" = 0. In other words, horizontal position "a" represents the axial position of the conductor when entering the coil, and horizontal position "b" represents the axial position of the conductor when leaving the coil. Subsequently, conductor 1 leaves coil 1b at horizontal position 0 and is routed at that horizontal position to enter the last coil 1a of phase L1. Conductor 1 leaves coil 1a in a plane at horizontal position +2, meaning that the plane has moved axially by two units, where one unit represents the expected minimum spatial distance between conductors of different phases. Similarly, wire 2 is routed from star terminal 211 to enter coil 2c at horizontal position 0, exit coil 2c at horizontal position +1, routed to enter coil 2b at horizontal position +1, exit coil 2b at horizontal position +1, routed to enter coil 2a at that horizontal position, and finally exit coil 2a at horizontal position +2, where it is routed to reach phase terminal L2. Similarly, wire 3 is routed from star terminal 211 to enter coil 3c at horizontal position 0, exit coil 3c at horizontal position +2, routed to enter coil 3b at horizontal position +2, exit coil 3b at horizontal position +2, routed to enter coil 3a at that horizontal position, and finally exit coil 3a at horizontal position +2, where it is routed to reach phase terminal L3. This routing scheme ensures that the routing plane of wires 1, 2, and 3 remains constant along substantially the entire pole chain 100, eliminating the need for wires to cross or exchange routing planes, thus enabling quick and simple laying operations. A similar wiring scheme can be achieved by placing wires in different cylindrical surfaces with radial distances at positions 0, +1, and +2.

[0058] The wiring of conductors 1, 2, and 3 from one coil to another in an axially separated plane is achieved by using multiple conductor guides and supports, which are preferably integrally formed with the winding core 200, such that after the winding operation is completed, when the straight pole chain 100 is rounded to its circular configuration, conductors 1, 2, and 3 remain in place.

[0059] In a preferred embodiment, each winding core 200 includes support pins 261a and 261b as support devices, which support conductors 1, 2, and 3 at dedicated wiring points between two adjacent coils. For example, in Figure 12Two support pins 261a and 261b are shown, and as described above, the support pins 261a and 261b are configured to support multiple wires in different planar or axial horizontal positions. However, more or fewer support pins can be provided to achieve this effect. The support pins 261a and 261b may include shoulders, which may have different diameters at different axial horizontal positions, or may have a conical shape to improve wire engagement and prevent unwanted movement of the wires. Additionally or alternatively, the support pins 261a and 261b may have a forked configuration to spatially separate and accommodate and support the wires. Support pins 261a and 261b are preferably positioned such that conductors 1, 2, and 3 are guided along a path from the winding core 200 of a pole tooth 131 to the winding core 200 of an adjacent pole tooth 131, the path passing near or intersecting the pivot axis, about which the adjacent pole tooth 131 pivots when the pole chain 100 is rounded to its circular configuration, such that the tension of conductors 1, 2, and 3 remains substantially constant and the conductors are securely held in place. Alternatively, support pins 261a and 261b may be preferably arranged such that the tension of conductors 1, 2, and 3 is slightly increased or decreased, for example, to obtain a specific tension considered ideal relative to the expected thermal expansion of the conductors during motor operation. Conductors 1, 2, and 3 may be routed via support pins 261a and 261b by only partially surrounding them, or may be wound around the pins more than one turn. The latter option allows the support pins 261a, 261b to provide a strain relief effect, ensuring that any tension in one conductor section is not completely transmitted to adjacent conductor sections. Furthermore, by winding the conductor around the pin more than once, unwanted axial movement of the conductor is impeded. If desired, arranging the conductors around the pin more than once and / or changing the winding direction of the pins between different conductors 1, 2, 3 of different phases L1, L2, L3 can also alter the wiring plane and further change the distance between conductors of different phases. Another guide device 260 can be provided at each winding core 200 and can be positioned such that, in particular, two conductors of 1, 2, 3 that pass through the respective winding core 200 and do not enter the winding space or coil of that winding core are guided on the guide device 260 between the support pins 261a, 261b to improve support function by increasing conductor tension and / or conductor contact angle around the support pins 261a, 261b. The guide device 260 can be configured to be elastic and apply the desired tension to the guided conductor. The support pins 261a, 261b and / or the guide device 260 may have one or more grooves or recesses that extend substantially perpendicular to the axis of the rotor 10 in order to improve the support function and prevent axial movement of the wires.

[0060] In another embodiment that can be combined with the above embodiments, the winding core 200 includes support devices 250a, 250b adjacent to the winding space or the coil space of the receiving coil, such as... Figure 4 and 12 As shown. Support device 250a is located on one side of pole tooth 131 in the circumferential direction and supports and guides the wires entering the coil, while support device 250b is located on the opposite side relative to pole tooth 131 and supports and guides the wires leaving the coil. Support devices 250a and 250b are preferably part of a coil space boundary portion that defines and restricts the space in which the coil is wound around pole tooth 131, and are separated or defined relative to the remaining coil space boundary portion by forming recesses in support device separators 251a and 251b, respectively. In this case, each wire 1, 2, 3 is routed from support pin 261a to the bottom wires of support device 250a and support device separator 251a to enter the coil space. The wires leaving the coil space are supported and guided by support device separator 251b and support device 250b, and are further routed to support pin 261b in the direction toward the next winding core 200 of the adjacent pole tooth 131. To route wiring from / to a desired wiring plane having a specific horizontal position "a" or "b", the support device separators 251a, 251b are preferably configured such that the corresponding recess depth is adapted to the desired wiring horizontal position "a" or "b". In other words, in a preferred further development of this embodiment, each winding core 200 has support device separators 251a, 251b formed in different ways, such that the wire enters and exits the coil space at the desired axial horizontal position. Thus, for example, the winding core 200 of coil 3c has a deep recess at the support device separator 251a providing the wiring horizontal position "a" = 0, and a shallow recess at the support device separator 251b providing the wiring horizontal position "b" = +2, while the winding core 200 of coil 2b has the same medium-depth recesses at both support device separators 251a, 251b for providing the same wiring horizontal position "a" = "b" = +1, which can be achieved from Figure 5 The table in the document is used to derive the results.

[0061] The support devices 250a, 250b and the support device separators 251a, 251b are preferably arranged and shaped such that, in addition to the wiring functions described above, they can provide strain relief effects to ensure the desired tension of the conductors 1, 2, 3, and can improve air circulation through the stator 20 by providing openings and channels for guiding air flow through the stator 20.

[0062] In a further improvement to the winding core 200, which can be combined with the aforementioned stator 20 embodiment, the winding core 200 includes a winding asymmetry device 270 and a winding shifting device 280, which allow the respective conductors 1, 2, 3 to enter the coil space of the winding core 200 without applying undesirable stress to the conductors and their coatings through stretching and compression. Such stretching or compression may occur when the entering conductors are covered by subsequent winding turns. To avoid such undesirable stress being applied to the entering conductors, the support device separator 251a may preferably have a recess in the form of an inclined channel or the winding asymmetry device 270, the inclined channel having an initial depth of at least one conductor diameter, such as... Figure 14 and 15 As shown, the conductor is gradually introduced into the coil space substantially in the winding direction (rather than perpendicular to the winding direction) and is not subjected to abrupt bending or kinking. Subsequent winding turns of the conductor can then be smoothly laid near the incoming conductor without applying any undesirable stress. The channel shape of the winding asymptotic device 270 can have a suitable width greater than one conductor diameter, allowing the conductor to move laterally within the channel before being covered by subsequent winding turns, and thus compensating for thermal expansion of the conductors outside the coil.

[0063] As an alternative to or supplement to the winding progressive device 270, the winding core 200 may include a winding shifting device 280, which takes the form of an inclined protrusion at the inner surface of the coil space boundary portion (wall) of the winding core 200, having a maximum protrusion height of at least one conductor diameter, and decreasing in height in the direction toward the outer surface of the coil, such as... Figure 14 and 15 As shown. The winding shifting device 280 is configured to push or move subsequent winding turns away from the incoming conductor, preventing them from applying unwanted stress to the incoming conductor. The winding aggression device 270 and the winding shifting device 280 reduce or prevent any reduction in the conductor's cross-sectional area during entry into the coil space or during the winding of subsequent winding layers. Such a reduction in the cross-sectional area of ​​the incoming conductor may also be caused by thermal stress during motor operation, resulting in changes in conductor tension or conductor movement.

[0064] like Figure 9 As shown, in another embodiment of the invention that can be combined with the above embodiments, the winding core 200 of the aforementioned embodiments may have coil space (winding space) boundary walls with different inclinations on the lateral side facing adjacent pole teeth 131, compared to the narrow side facing the axial direction. Specifically, as... Figure 9As shown, the angle γ at the intersection 221 of the lateral sidewall and the bottom of the winding space is larger than the angle α at the intersection 220 of the narrow sidewall and the bottom of the winding space, and the difference is angle β, thus γ = α + β. The difference β between these angles is preferably set to 5° to 25°, more preferably to 10° to 15°. In this way, the winding space is expanded on the lateral side of the pole teeth, i.e., there is more winding space, thereby enabling a more uniform layup of the winding layers. Therefore, a more uniform "orthogonal" winding can be obtained, with less expansion on the sides of the coil.

[0065] In another embodiment, the winding core 200 includes a pickup slot or recess 217 located outside the circular pole chain 100. For example... Figure 4 and Figure 7 As shown, the pickup slot is configured to engage with a workpiece clamp 318, which holds the pole chain 100 during the winding operation and / or during bending when the pole chain 100 is rounded into its circular configuration. Additionally, a positioning shoulder 219 may be provided on the winding core, which is also engaged by the workpiece clamp or retainer 318. Combined with the optional support web 215 located on the narrow side of the winding core 200 and the optional winding core ridge 222 on the outside of the circular pole chain 100, the operation of both the straight and circular configurations of the pole chain 100 is improved throughout the manufacturing process. This is because when the pole chain 100 is placed on a surface between two processing steps, the protruding ridge 222 and the protruding support web 215 prevent the enameled wires 1, 2, 3 from contacting the surface, which could potentially damage the wires and their insulation coating. In addition, the support web 215 and the winding core ridge 222 can also be used to transmit axial and / or circumferential forces to other components of the motor through form fit or force fit, so that the driving force generated during motor operation can be received and properly transferred.

[0066] Each and each individual feature in the above embodiments, individually or in combination, enables or facilitates the optional use of aluminum conductors instead of copper conductors by reducing the likelihood of insulation defects and short circuits due to the more difficult operating characteristics of aluminum conductors, without increasing the overall size of the motor stator and without increasing the motor's failure rate. This invention enables manufacturers of motors (e.g., BLDC motors) to alternatively use aluminum or copper conductors for motors with the same stator design or the same design and construction. Aluminum conductors or enameled aluminum conductors may also include conductors made of aluminum alloys. Furthermore, self-bonding conductors can be used as conductors 1, 2, and 3.

[0067] The stator of the present invention can be used in an electric motor having an internal rotor 10. The design of the pole chain 100 can be adjusted so that the above embodiments can also be implemented with an electric motor having an external rotor (in which case, after rounding the pole chain to its circular configuration, the pole teeth are radially outward). The electric motor can be an AC motor or a DC motor, and can be electronically commutated. The pump having the stator according to the present invention is preferably designed as a wet rotary pump, which includes a rotor can 30 located in the gap between the stator 20 and the rotor 10.

[0068] like Figures 17 to 20 As shown, in a preferred embodiment, the pump is a centrifugal pump, including an axial inlet 40 and a radial outlet 50. The rotor 10 is housed within a rotor tank 30, which is part of the pump housing element 32, such that the rotor operates within the pumped liquid while the stator 20 remains dry and attached to the outside of the rotor tank 30. The rotor 10 preferably comprises a single ferrite body 12 having at least four magnetic poles, wherein the ferrite body 12 has transverse circumferential magnetization. The ferrite body 12 preferably has an annular shape; "transverse circumferential magnetization" refers to... Figure 19 The magnetization shown has alternating magnetic N and S poles on the outer cylindrical surface, while the inner cylindrical surface of the ferrite body 12 (ferrite ring) has essentially no magnetic poles. Alternatively, the ferrite body may consist of multiple segments. The ferrite body is attached to the rotor core element 15, which is typically a plastic body, and is attached to the rotor shaft 17 or a portion of the rotor shaft 17. This transverse-circumferential magnetization improves the magnetic field distribution at and within the gap between the stator 20 and the rotor 10, thereby improving pump performance, energy efficiency, and operational smoothness through stronger and more sinusoidal magnetic flux conduction between the rotor 10 and the stator 20, particularly when the stator 20 preferably has narrow slots between adjacent pole teeth 131. Preferably, the ferrite body 12 (ferrite ring) includes at least one mechanically stabilizing additive, such as manganese, cobalt, or lanthanum. In this way, an additional sheath for the ferrite body 12 is unnecessary, even when operating in corrosive media, such as those found in dishwashers and washing machines (which may contain alkaline or acidic solutions). The combination of pole chain 100 (which has a minimum distance between the radial inner surfaces (slot width) of the pole teeth 131 of a wet rotor type motor with water (pumping medium) in the magnetic gap) and transverse-circumferential magnetization is particularly advantageous for optimizing the performance (power), smooth operation and efficiency of pump p.

[0069] exist Figure 19The diagram illustrates the magnetization direction of a ferrite 12 with six poles in transverse-circumferential magnetization. Preferably, the orientation of the poles results in each of the six single poles S, N on the outer peripheral surface of the ferrite body 12 being circumferentially aligned with a corresponding latch 16 disposed on the outer peripheral surface of the rotor core element 15 supporting the ferrite body 12. The latch 16 transmits torque from the ferrite body 12 (permanent magnet) to the rotor shaft 17 via the rotor core element 15 in a form-fit manner. This arrangement of the poles N, S and the latch 16 increases the radial thickness of the ferrite 12 between two adjacent poles, thereby optimizing and enhancing magnetic flux conduction within the ferrite 12. Thus, any additional rotor laminations for providing the back iron are unnecessary. This reduces assembly complexity and manufacturing costs. Furthermore, this design helps minimize the risk of cracking, which may occur during manufacturing or operation of the ferrite body due to factors such as temperature variations, shrinkage during sintering, or anisotropy of the magnet 12. These cracks primarily occur and grow at the boundary between two opposite magnetic poles, in other words, in the middle between the various magnetic pole regions of the ferrite body 12. As described above, the provision of the latching portion 16 and the complementary groove in shape in the inner cylindrical surface of the ferrite body 12 substantially reduces the risk of crack initiation and / or crack growth. The latching portion 16 and the corresponding groove in the ferrite body 12 can have a circular or square / rectangular shape. Preferably, as described above, the latching portion 16 and the corresponding groove in the ferrite 12 are located on the inner cylindrical surface of the ferrite 12. Alternatively, the latching portion 16 and the corresponding groove in the ferrite 12 can be radially aligned on the axial end face of the ferrite 12, while the rotor core element 15 includes a disc-shaped end element and two axial ends that surround the ferrite 12 and carry the radially oriented latching portion 16 (not shown).

[0070] According to another aspect of the invention, such as Figure 20 As shown, the housing element 32 may include longitudinally (i.e., axially) extending fins 34 (sometimes also referred to as split tubes 30) on the outer surface of the rotor tank 30. These fins 34 improve the stability of the thin wall of the cylindrical rotor tank 30, allowing the wall to be made thinner, taking into account the pressure difference that occurs between the inside and outside of the pump housing. Furthermore, in this embodiment, each pole tooth 131 of the pole chain 100 is received between two adjacent fins 34, such that the fins 34 protrude into the groove between the pole teeth, and help anchor the pole chain 100 to the pump housing and transfer the torque applied to the pole chain 100 during operation. Alternatively, as... Figure 20 As shown, the housing element 32 may have guide protrusions 36, 38 that project radially inward from the cylindrical wall of the housing element 32 and extend in the axial direction, and are configured to be received in complementary engagement grooves formed on the outer peripheral surface of the pole chain 100, for example... Figure 4 The guide protrusions 36 and 38, as shown in the groove 217, help guide the pole chain 100 to the correct position when it is mounted on the housing element 32, and also help cooperate with the fins 34 to transfer torque. Furthermore, at least one guide protrusion 38 may have a different size or shape than the other guide protrusions 36 to prevent the pole chain 100 from being mounted in the wrong circumferential direction and to ensure that the star terminal retainer 210 and the phase terminal retainer 212 are in the correct predetermined positions. Figure 21 As shown, the motor cover 40 may also have a similar guide protrusion 44 configured to engage with a groove formed on the outer peripheral surface of the pole chain 100. In this way, proper axial and circumferential positioning of the motor cover 40 can be ensured when the motor cover 40 is mounted on the pole chain 100 and the housing element 32. The housing element 32 and the motor cover 40 may have screw holes 33, 43 for receiving screws (not shown) to attach the motor cover 40 to the housing element 32. In a particularly preferred embodiment, these screw holes 33, 43 are omitted, and the guide protrusions 36, 38, 44 are provided with a snap-fit ​​mechanism (not shown) that engages the protrusion 44 on the protrusions 36, 38. This snap-fit ​​mechanism is preferably non-releasable, but can also be formed as releasable if desired. Because the size and / or shape of the guide protrusions 36, 38 and the corresponding protrusion 44 ensure that the pole chain 100 can only move fully to its final desired position on the housing element 32 in the correct direction, a pole chain 100 that is not circumferentially oriented will protrude from the housing element 32 in the axial direction to the extent that it prevents the snap-fit ​​mechanisms of the protrusions 36, 38 and 44 from engaging. In this way, incorrect assembly of the housing element 32, the pole chain 100, and the motor cover 40 is impossible. Furthermore, the snap-fit ​​mechanisms reduce the number of parts and the complexity of assembly, thereby reducing manufacturing costs. Alternatively, the groove 217 of the pole chain 100 may be provided with a snap-fit ​​mechanism configured to engage with the protrusions 36, 38 of the housing element 32, and another snap-fit ​​mechanism configured to engage with the protrusion 44 of the motor cover 40. Also in this alternative embodiment, if the orientation of the corresponding components is incorrect, assembly (i.e., snap-fit ​​engagement) of the pole chain 100 with the housing element 32 and the motor cover 40 is prevented. Similarly, in this alternative embodiment, if the orientation of the corresponding component is incorrect, assembly (i.e., snap-fit ​​engagement) of the pole chain 100 with the housing element 32 and the motor cover 40 is prevented.

[0071] Reference Marker

[0072] 1. Electrical conductor of phase L1

[0073] The coils of phases L1 (1a, 1b, 1c)

[0074] The electrical conductors of phase L2

[0075] The coils of phases L2 (2a, 2b, 2c)

[0076] 3-phase L3 electrical conductors

[0077] The coils of phases L3 (3a, 3b, 3c)

[0078] L1 phase L1 terminal

[0079] L2 phase L2 terminal

[0080] L3 phase L2 terminal

[0081] 10 rotors

[0082] 12 Ferrite Body

[0083] 15 Rotor core components

[0084] 17 Rotor shaft

[0085] 20 stators

[0086] 30 Rotor Tank

[0087] 32 Motor housing components

[0088] 33 Screw holes

[0089] 34 fins

[0090] 36, 38 guiding protrusions

[0091] 40 Motor Cover

[0092] 43 Screw holes

[0093] 44. Guide protrusion

[0094] 100 Extreme Chain

[0095] 110 Connecting part

[0096] 111 stacked pieces

[0097] 112 Winding Tool Path

[0098] 113 End of winding tool

[0099] 116. The longitudinal axis of the electric motor

[0100] 120 iron sheet

[0101] 130 Extreme Part

[0102] 131 Pole Tooth

[0103] 132 Bending section

[0104] 200 winding core

[0105] 210 Star Terminal Retainer

[0106] 211 Star Terminal

[0107] 212 Phase Terminal Holder

[0108] 215 Supporting web

[0109] 217 Pickup Slot

[0110] 219 Positioning Shoulder

[0111] 220° α

[0112] 221 Angle γ

[0113] 222 Winding core ridge

[0114] 250a, 250b support components

[0115] 251a, 251b Support device separator

[0116] 260 boot device

[0117] 261a, 261b support pins

[0118] 270 winding asymptotic device

[0119] 280 winding shifting device

[0120] 318 Workpiece Fixture

Claims

1. A pump for wading operation equipment, comprising an electric motor, the electric motor including: The rotor (10) includes a ferrite body (12) having at least four magnetic poles, wherein the ferrite body (12) has transverse-circumferential magnetization; Stator (20), including: A pole chain (100) is made of a stack (111) of multiple straight transformer laminations (120) and is rounded into a circular structure by bending the stacked transformer laminations (120). The pole chain (100) has multiple pole portions (130), each pole portion including pole teeth (131). Multiple winding cores (200) are attached to corresponding pole teeth (131) for accommodating coils (1a, 1b, 1c, 2a, 2b, 2c, 3a, 3b, 3c) comprising three conductors (1, 2, 3); In this three-phase winding, the conductors (1, 2, 3) of each phase (L1, L2, L3) are spatially separated and are not in contact with each other between adjacent winding cores (200) around the pole chain (100) and along the axial end face of the pole chain (100); and The conductors (1, 2, 3) are supported and guided such that the position of the conductors relative to the pole chain (100) is maintained when the pole chain (100) is rounded from its straight configuration to its circular configuration. The pump also includes a housing element (32) having a rotor tank (30) located between the rotor (10) and the stator (20), wherein the housing element (32) includes a plurality of longitudinally extending fins (34) located on the outer surface of the rotor tank (30); The housing element (32) includes a plurality of guide protrusions (36, 38) that protrude radially inward from the cylindrical wall of the housing element (32) and extend in the axial direction of the cylindrical wall, and are configured to be received in complementary engagement grooves formed on the outer peripheral surface of the pole chain (100). At least one of the guide protrusions (38) has a different size or shape compared to the other guide protrusions (36) to prevent the pole chain (100) from being installed in the wrong circumferential direction.

2. The pump according to claim 1, The ferrite body (12) is made in single piece and includes at least one of manganese, cobalt or lanthanum as a mechanical stabilizing additive.

3. The pump according to claim 1 or 2, The conductors (1, 2, 3) are routed in three axially separated wiring planes, which have different axial horizontal positions along the axis of the circular polar chain (100), wherein each conductor (1, 2, 3) is routed in a corresponding one of the wiring planes.

4. The pump according to claim 1, Each winding core (200) also includes a support device (250a, 250b) configured to support and guide the corresponding wire (1, 2, 3) to a corresponding one of the separate wiring planes when the coil on the winding core (200) is allowed to enter or leave.

5. The pump according to claim 1, Each winding core (200) further includes support separators (251a, 251b) formed as recesses in the coil space boundary wall of the winding core (200), the recesses having a set depth such that the bottom line of the recesses is located at the axial horizontal position of one of the wiring planes.

6. The pump according to claim 5, At least one of the support separators (251a) also includes a winding asymmetric device (270).

7. The pump according to claim 1, The winding core (200) also includes a winding shifting device (280) located on the inner wall of the coil space of the winding core (200).

8. The pump according to claim 1 or 2, Each winding core (200) also includes a support pin (261a, 261b) configured to support the conductors (1, 2, 3) and guide the conductors from one winding core (200) to an adjacent winding core (200) in an axially separated wiring plane.

9. The pump according to claim 8, The support pins (261a, 261b) include shoulders or recesses to support the wires (1, 2, 3) and prevent axial movement of the wires (1, 2, 3).

10. The pump according to claim 1, Compared to the tilt angle (α) of the narrow side of the coil space facing the stator axial direction, the transverse sidewall of the coil space of the winding core (200) facing the stator circumferential direction has a larger tilt angle (γ), wherein the difference (β) between angles (α) and (γ) is set to 5° to 25°.

11. The pump according to claim 1, The conductors (1, 2, 3) are enameled wires made of aluminum or aluminum alloy.

12. The pump according to claim 1, Each single magnetic pole (N, S) on the outer peripheral surface of the ferrite body (12) is circumferentially aligned with a latching portion (16) provided on the outer peripheral surface of the rotor core element (15) that carries the ferrite body (12).

13. The pump according to claim 1, The pump in question is a pump used in household appliances.

14. The pump according to claim 13, The household appliance is a dishwasher or a washing machine.

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