Stator, electric motor, electric power steering system, and vehicle

Abstract

This invention discloses a stator, a motor, an electric power steering system, and a vehicle. The stator includes a ring-shaped busbar and a stator insulation frame. A downwardly extending buckle is provided at the lower end of the busbar. The stator insulation frame is located below the busbar and is snapped into place. The stator insulation frame includes multiple frame units arranged in a ring. Each frame unit includes an outer frame plate, an inner frame plate, and a winding portion. The multiple outer frame plates form an outer contour, and the multiple inner frame plates form an inner contour. The outer contour surface of the outer frame plate and the inner contour surface of the inner frame plate are concentric arc surfaces. A snap-fit ​​groove is provided on the outer contour surface to engage with the buckle, and a guide groove is also provided on the outer contour surface, located above the snap-fit ​​groove. According to the stator of this invention, the guide groove on the outer contour surface, located above the snap-fit ​​groove, provides guidance for the buckle to move towards and engage with the snap-fit ​​groove, thereby facilitating the alignment of the buckle with the snap-fit ​​groove.

Description

Technical Field

[0001] This invention relates to the field of motor-related technologies, and in particular to a stator, a motor, an electric power steering system, and a vehicle. Background Technology

[0002] An electric motor is a device that converts electrical energy into mechanical energy. For example, the steering motor used in a vehicle's electric power steering system generates a rotating magnetic field through stator windings, which acts on the rotor to create a magnetoelectric torque, thus causing the motor to rotate. In the stator, the stator core mates with the stator insulation frame. Wires are wound onto the stator insulation frame, and the leads are connected to busbars. The busbars are snap-fitted to the upper end of the stator insulation frame. Currently, during the snap-fit ​​installation of the busbars and stator insulation frame, alignment between the busbars and the stator insulation frame is difficult, resulting in low assembly efficiency. Summary of the Invention

[0003] The present invention aims to at least solve one of the technical problems existing in the prior art. To this end, a first aspect of the present invention provides a stator that facilitates the alignment and installation of the busbar and the stator insulation frame, thereby improving assembly efficiency.

[0004] A second aspect of the present invention provides an electric motor including the stator described above.

[0005] A third aspect of the present invention provides an electric power steering system including the above-described motor.

[0006] A fourth aspect of the present invention provides a vehicle including the above-described electric power steering system.

[0007] According to a first aspect of the present invention, a stator includes an annular busbar and a stator insulation frame. The lower end of the busbar is provided with a downwardly extending buckle. The stator insulation frame is located below the busbar and is snapped and fixed to it. The stator insulation frame includes a plurality of frame units arranged in a ring. Each frame unit includes an outer frame plate, an inner frame plate, and a winding portion located between the outer frame plate and the inner frame plate. The plurality of outer frame plates form the outer contour of the stator insulation frame, and the plurality of inner frame plates form the inner contour of the stator insulation frame. The outer contour surface of the outer frame plate and the inner contour surface of the inner frame plate are concentric arc surfaces. The outer contour surface of the outer frame plate is provided with a fastening groove that engages with the buckle, and the outer contour surface of the outer frame plate is also provided with a guide groove located above the fastening groove.

[0008] The stator according to the embodiments of the present invention has at least the following beneficial effects: a guide groove is provided on the outer contour surface of the outer frame plate, which is located above the fastening groove. The guide groove can provide guidance for the process of the buckle moving towards the fastening groove and engaging, thereby facilitating the alignment of the buckle with the fastening groove and improving the assembly efficiency of the busbar and the stator insulation frame.

[0009] According to some embodiments of the present invention, the guide groove is disposed at the connection between the outer contour surface of the outer frame plate and the upper end surface of the outer frame plate, and the bottom surface of the guide groove is configured as a first guide surface, which is inclined from top to bottom toward the radially outer side of the outer contour.

[0010] According to some embodiments of the present invention, the bottom surface of the guide groove is set as a plane, the cross section of the guide groove along the radial direction of the outer contour is triangular, the maximum thickness of the outer frame plate along the radial direction of the outer contour is S1, the height of the cross section of the guide groove along the radial direction of the outer contour is S2, and the inclination angle of the first guide surface relative to the axial direction of the outer contour is θ, wherein the magnitude of θ satisfies: 0° < θ < arctan(S1 / S2).

[0011] According to some embodiments of the present invention, the buckle includes a fixing part and a hook part, the fixing part being connected to the busbar; the hook part being connected to the fixing part and used to hook and engage with the fastening groove; wherein, the lower end of the hook part is provided with an inclined second guide surface on the radial inner side of the outer contour, the inclination angle of the second guide surface relative to the axial direction of the outer contour is γ, the inclination angle of the first guide surface relative to the axial direction of the outer contour is θ, and the magnitudes of γ and θ satisfy: γ > θ.

[0012] According to some embodiments of the present invention, the frame unit is provided with a slot for inserting the stator core, the slot extending radially through the outer frame plate, the winding portion and the inner frame plate along the outer contour, and the fastening groove is provided at the connection between the outer contour surface of the outer frame plate and the upper end wall of the slot.

[0013] According to some embodiments of the present invention, the connection between the upper end wall of the card slot and the two side walls of the card slot along the circumferential direction of the outer contour, and the connection between the lower end wall of the card slot and the two side walls of the card slot along the circumferential direction of the outer contour, are all set as right-angle transitions.

[0014] According to some embodiments of the present invention, the frame unit includes a first insulating frame and a second insulating frame located below the first insulating frame. The lower end of the first insulating frame is provided with a first insertion groove, and the upper end of the second insulating frame is provided with a second insertion groove that is inserted and fixed to the first insertion groove. The first insertion groove is formed on one side of the inner side and the outer side of the lower edge of the first insulating frame, and the second insertion groove is formed on the other side of the inner side and the outer side of the upper edge of the second insulating frame. The inner side is the side close to the center of the slot, and the outer side is the side opposite to the center of the slot relative to the inner side. The axial height of the first insertion groove along the outer contour is E1, and the axial height of the second insertion groove along the outer contour is E2. E1 and E2 satisfy: E1=E2≥0.5mm.

[0015] According to some embodiments of the present invention, the fastening groove is connected to the guide groove, or the fastening groove and the guide groove are spaced apart.

[0016] According to some embodiments of the present invention, the outer frame plate is provided with an inlet groove and an outlet groove. Along the circumferential direction of the outer contour, the inlet groove and the outlet groove are respectively located on both sides of the guide groove and the fastening groove. The inlet groove and the outlet groove are both provided at the upper end of the outer frame plate, or one of the inlet groove and the outlet groove is provided at the upper end of the outer frame plate and the other is provided at the lower end of the outer frame plate.

[0017] An electric motor according to a second aspect embodiment of the present invention includes a stator according to a first aspect embodiment of the present invention.

[0018] The motor according to the embodiments of the present invention has at least the following beneficial effects: by providing a guide groove above the snap-fit ​​groove, the alignment of the snap-fit ​​and the snap-fit ​​groove is facilitated, thereby improving the assembly efficiency of the busbar and the stator insulation frame, and correspondingly improving the manufacturing efficiency of the motor.

[0019] An electric power steering system according to a third aspect of the present invention includes a motor according to a second aspect of the present invention.

[0020] The electric power steering system according to embodiments of the present invention has at least the following beneficial effects: the guiding action of the guide groove facilitates the alignment of the buckle and the engagement groove, thereby improving the production efficiency of the electric power steering system.

[0021] A vehicle according to a fourth aspect of the present invention includes an electric power steering system according to a third aspect of the present invention.

[0022] The vehicle according to an embodiment of the present invention has the beneficial effects of the electric power steering system described above.

[0023] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0024] The present invention will be further described below with reference to the accompanying drawings and embodiments, wherein:

[0025] Figure 1 This is a three-dimensional structural diagram of the stator according to an embodiment of the present invention;

[0026] Figure 2 yes Figure 1 A magnified view of a section at point A in the middle;

[0027] Figure 3 This is a three-dimensional structural diagram of the stator busbar according to an embodiment of the present invention;

[0028] Figure 4 yes Figure 3 A magnified view of a section at point B in the middle;

[0029] Figure 5 for Figure 1 A front sectional view;

[0030] Figure 6 yes Figure 5 A magnified view of a section at point C;

[0031] Figure 7 This is a partial structural schematic diagram of the stator insulation frame according to an embodiment of the present invention;

[0032] Figure 8 This is a partial structural schematic diagram of the first insulating frame of the stator insulating frame according to an embodiment of the present invention;

[0033] Figure 9 yes Figure 8 A partial structural schematic diagram of the first insulating frame from another angle is shown;

[0034] Figure 10 yes Figure 8 A partial structural schematic diagram of the first insulating frame from another angle is shown;

[0035] Figure 11 yes Figure 8 A front view of the first insulating frame is shown;

[0036] Figure 12 yes Figure 8 A top view of the first insulating frame is shown;

[0037] Figure 13 yes Figure 8A side view of the first insulating frame is shown;

[0038] Figure 14 This is a partial structural schematic diagram of the second insulating frame of the stator insulating frame according to an embodiment of the present invention.

[0039] Figure label:

[0040] Stator 1000, stator insulation frame 100, frame unit 101, buckle 102, stator core 103, second guide surface 104, clearance groove 105, first insulation frame 110, inlet groove 111, outlet groove 112, first winding groove 113, first insertion groove 114, corner 115, second insulation frame 120, second winding groove 121, second insertion groove 122, winding position 130, buckle 140, guide groove 150, first guide surface 151, fastening groove 160, outer frame plate 170, inner frame plate 180, winding part 190;

[0041] Busbar 200, terminal 201, ring bracket 202, strip bracket 203, fixing part 204, hook part 205, elastic hook 206, wiring terminal 207, busbar 208, inlet line 210, outlet line 220. Detailed Implementation

[0042] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0043] In the description of this invention, the use of terms such as "first," "second," etc., is for the purpose of distinguishing technical features only and should not be construed as indicating or implying relative importance, or implicitly indicating the number of technical features indicated, or implicitly indicating the order of the technical features indicated.

[0044] In the description of this invention, it should be understood that the orientation descriptions, such as up, down, left, right, front, back, etc., are based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0045] In the description of this invention, it should be noted that, unless otherwise explicitly defined, terms such as "setting," "installation," and "connection" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this invention in conjunction with the specific content of the technical solution.

[0046] As is well known, an electric motor utilizes a rotating magnetic field generated by stator windings, which acts on the rotor to create a magnetoelectric torque, thereby causing the motor to rotate. In the stator, the stator core and stator insulation frame cooperate, with wires wound around the insulation frame and leads connected to busbars. The busbars are then snapped into place with the insulation frame. However, in existing stators, the busbars and insulation frame are difficult to align when snapped into place, resulting in low assembly efficiency. Therefore, this invention proposes a stator, specifically referring to... Figures 1 to 14 As shown.

[0047] Reference Figure 1 , Figure 5 , Figure 6 As shown, the stator 1000 of the first aspect embodiment of the present invention includes a busbar 200 and a stator insulation frame 100 located below the busbar 200. The lower end of the busbar 200 is provided with a downwardly extending buckle 102. The stator insulation frame 100 is snapped and fixed to the busbar 200. The stator insulation frame 100 includes a plurality of frame units 101 arranged in a ring. The frame unit 101 includes an inner frame plate 180, an outer frame plate 170, and a winding portion 190 located between the inner frame plate 180 and the outer frame plate 170. The outer contour surface of the outer frame plate 170 is provided with a fastening groove 160 suitable for cooperating with the buckle 102. The outer contour surface of the outer frame plate 170 is also provided with a guide groove 150, which is correspondingly provided with the fastening groove 160 and located above the fastening groove 160. Understandably, the snap fastener 102 is elastic, and it can undergo elastic deformation during the engagement process with the locking groove 160. The function of the snap fastener 102 and the locking groove 160 is to snap and fix the stator insulation frame 100 and the busbar 200 together. The snap fastener 102 can be configured to have a protruding structure at its lower end, and correspondingly, the locking groove 160 is configured as a groove or through hole that mates with the protruding structure.

[0048] It should be noted that multiple frame units 101 are arranged in a ring to form a stator insulation frame 100. The stator insulation frame 100 is cylindrical in shape, and its cross-section is approximately circular. The outline enclosed by the outer frame plates 170 of all frame units 101 is the outer outline of the stator insulation frame 100, and the outline enclosed by the inner frame plates 180 of all frame units 101 is the inner outline of the stator insulation frame 100. The outer and inner outlines are concentric rings. The outer outline surface of the outer frame plate 170 is the outer surface of the outer outline, and the inner outline surface of the inner frame plate 180 is the inner surface of the inner outline. The outer outline surface of the outer frame plate 170 and the inner outline surface of the inner frame plate 180 are concentric arc surfaces. Based on this, the radial direction of the outer outline can be understood as the radial direction of the stator insulation frame 100, the circumferential direction of the outer outline can be understood as the circumferential direction of the stator insulation frame 100, and the axial direction of the outer outline can be understood as the axial direction of the stator insulation frame 100.

[0049] It is understandable that when the guide groove 150 is located above the fastening groove 160, the center line of the circumferential width of the guide groove 150 along the outer contour and the center line of the circumferential width of the fastening groove 160 along the outer contour roughly coincide in the radial direction of the outer contour. This allows the buckle 102 to be aligned with the fastening groove 160 after being guided by the guide groove 150, so as to facilitate the snap-fit ​​between the buckle 102 and the fastening groove 160.

[0050] Reference Figure 1 , Figure 2 As shown, it should be noted that the stator 1000 also includes a stator core 103. The stator insulation frame 100 is connected to the stator core 103. Specifically, the frame unit 101 forms a slot 140, which radially penetrates the outer frame plate 170, the winding portion 190, and the inner frame plate 180 along its outer contour. A fastening groove 160 is provided at the connection between the outer contour surface of the outer frame plate 170 and the upper end wall of the slot 140. The stator core 103 is secured within the slot 140. It can be understood that, referring to... Figure 6 , Figure 7 As shown, to facilitate the installation of the stator core 103, the frame unit 101 includes a first insulating frame 110 and a second insulating frame 120 arranged vertically. The first insulating frame 110 and the second insulating frame 120 are snap-fitted together. The guide groove 150 and the fastening groove 160 are both provided on the outer frame plate 170 of the first insulating frame 110. Part of the winding portion 190 is located on the first insulating frame 110, and part is located on the second insulating frame 120. A winding position 130 for accommodating the winding assembly (not shown in the figure) is provided around the winding portion 190. The frame unit 101 can provide support for the winding assembly and ensure insulation between the stator core 103 and the winding assembly. It should be noted that the first insulating frame 110 and the second insulating frame 120 can be plastic parts and are integrally molded structures.

[0051] For details, see Figure 7 , Figure 8 and Figure 14As shown, a first insertion slot 114 is provided at the lower end of the first insulating frame 110, and a second insertion slot 122 is provided at the upper end of the second insulating frame 120. The first insertion slot 114 and the second insertion slot 122 are engaged and fixed together, so that the first insulating frame 110 and the second insulating frame 120 are connected as a whole. The first insertion slot 114 is formed on the inner side of the lower edge of the first insulating frame 110 to form an L-shaped stepped structure, and the second insertion slot 122 is formed on the outer side of the upper edge of the second insulating frame 120 to form an L-shaped stepped structure. The inner side is the side close to the center of the slot 140, and the outer side is the side opposite to the center of the slot 140. The stepped structure of the first insertion slot 114 can be inserted into the stepped structure of the second insertion slot 122, so that the first insulating frame 110 and the second insulating frame 120 are connected. The structure is simple and practical, and the installation is convenient and quick.

[0052] It should be further explained that, referring to Figure 8 and Figure 14 As shown, the axial height of the first insertion groove 114 along its outer contour is E1, and the axial height of the second insertion groove 122 along its outer contour is E2. E1 and E2 satisfy: E1 = E2 ≥ 0.5 mm. This arrangement allows for a tighter fit between the first insertion groove 114 and the second insertion groove 122, ensuring a stable connection. It should be noted that the first insertion groove 114 and the second insertion groove 122 are not limited to the stepped structure shown in the above embodiment. For example, the first insertion groove 114 and the second insertion groove 122 can be connected by a snap-fit ​​method, which will not be elaborated further.

[0053] It should be noted that, referring to Figure 7 As shown, the inner sides of the first insulating frame 110 and the second insulating frame 120 are respectively provided with slots 140 that match the teeth (not shown) of the stator core 103. The first insulating frame 110 and the second insulating frame 120 are generally saddle-shaped. The lower end of the first insulating frame 110 is connected to the upper end of the second insulating frame 120, so that the slots 140 of the two insulating frames can be engaged with the teeth of the stator core 103. At the same time, the upper end of the first insulating frame 110 and the lower end of the second insulating frame 120 have a recessed winding position 130. The winding position 130 surrounds the inner frame plate 180 and the outer frame plate 170 of the stator insulating frame 100, and the winding can be wound inside the winding position 130 to form a winding group with a stable and reliable structure.

[0054] Understandably, referring to Figure 1 , Figure 2As shown, the stator insulation frame 100 is wrapped around the stator core 103, and then wires are wound on the stator insulation frame 100 to make winding groups. Each winding group has an inlet wire 210 and an outlet wire 220. After the winding groups are completed, the busbar 200 is fastened to the first insulation frame 110 to fix the busbar 200 on the stator core 103. Then, the inlet wire 210 and outlet wire 220 on each first insulation frame 110 are connected to the terminal block 207 of the busbar 200 through the inlet slot 111 and outlet slot 112, respectively. In this embodiment, the terminal block 207 adopts a hook structure, and the inlet wire 210 and outlet wire 220 are respectively welded to the corresponding hooks. Thus, the inlet wire 210 end and outlet wire 220 end of each winding group are gathered together by the busbar 200 to form the stator 1000, which has a more compact and reliable structure.

[0055] It should be noted that, referring to Figure 1 , Figure 2 As shown, the busbar 200 includes a frame, multiple busbars 208, and multiple terminals 201. The frame is an insulating component and can be injection molded. The frame supports the multiple busbars 208 and the multiple terminals 201. The busbars 208 are electrically connected to the terminals 310. The frame includes an annular support 202 and multiple strip supports 203 connected to the annular support 202. To facilitate snap-fit ​​fixing to the stator insulation frame 100, the lower end of the strip supports 203 is provided with multiple clips 102.

[0056] Specifically, the buckle 102 includes: a fixing part 204 and a hook part 205, such as Figure 3 , Figure 4 As shown. The fixing part 204 is connected to the strip-shaped bracket 203, and the hook part 205 is connected to the fixing part 204. At least one hook part 205 of the buckle 102 includes a plurality of spaced elastic hooks 206, such as... Figure 7 As shown, an avoidance groove 105 is formed between adjacent elastic hooks 206. During the assembly process, adjacent elastic hooks 206 can move closer to each other under the squeezing force, thereby reducing the size of the buckle 102. This facilitates the buckle 102 to quickly and smoothly hook and engage with the fastening groove 160. After hooking, the elastic hook 206 will be reset and deformed, and fit tightly with the fastening groove 160, thereby improving the connection strength.

[0057] According to an embodiment of the present invention, the stator 1000 has a guide groove 150 located above the fastening groove 160 on the upper end of the outer contour surface of the outer frame plate 170 of the stator insulation frame 100. The guide groove 150 can provide guidance for the process of the buckle 102 of the busbar 200 moving and engaging with the fastening groove 160, thereby facilitating the alignment of the buckle 102 with the fastening groove 160, improving the assembly efficiency of the busbar 200 and the stator insulation frame 100, and reducing the overall manufacturing cost of the stator 1000.

[0058] In some embodiments, refer to Figure 6 , Figure 7 As shown, the guide groove 150 is disposed at the connection between the outer contour surface of the outer frame 170 plate and the upper end surface of the outer frame plate 170. The bottom surface of the guide groove 150 is configured as a first guide surface 151, which is inclined from top to bottom toward the radially outer side of the outer contour. Specifically, the guide groove 150 is a notch disposed at the upper periphery of the outer frame plate 170, thereby facilitating the formation of the guide groove 150.

[0059] Specifically, refer to Figure 8 , Figure 13 As shown, the bottom surface of the guide groove 150 is set as a plane, the radial cross-section of the guide groove 150 is triangular, the maximum thickness of the outer frame plate 170 along the radial direction of the outer contour is S1, the height of the cross-section of the guide groove 150 along the radial direction of the outer contour is S2, and the inclination angle of the first guide surface 151 relative to the axial direction of the outer contour is θ, where the magnitude of θ satisfies the formula: 0° < θ < arctan(S1 / S2). Through the above settings, the guiding effect of the guide groove 150 can be improved while ensuring the strength of the stator insulation frame 100. If θ > arctan(S1 / S2), it means that the upper edge of the guide groove 150 is lower than the upper edge of the stator insulation frame 100, which will reduce the overall strength of the stator insulation frame 100 and affect its service life. If θ is too small, the guiding effect of the guide groove 150 will deteriorate.

[0060] It should be noted that, referring to Figure 4 , Figure 13 As shown, the lower end of the hook portion 205 has an inclined second guide surface 104 on its inner side along the radial direction of the outer contour. The inclination angle of the second guide surface 104 relative to the axial direction of the outer contour is γ, and the inclination angle of the first guide surface 151 relative to the axial direction of the outer contour is θ. The magnitudes of γ and θ satisfy: γ > θ. This arrangement reduces the friction between the buckle 102 and the bottom surface of the guide groove 150, facilitating the fastening and assembly of the buckle 102.

[0061] It should be noted that, referring to Figure 8As shown, the width of the guide groove 150 along the circumferential direction of its outer contour is W1, and the width of the fastening groove 160 along the circumferential direction of its outer contour is W2. The sizes of W1 and W2 satisfy: W1 ≥ W2. Therefore, the buckle 102 can easily enter the guide groove 150 and move along the guide groove 102 to reach the fastening groove 160.

[0062] Understandably, referring to Figure 7 , Figure 8 As shown, the slot 140 radially penetrates the outer frame plate 170, the winding portion 190, and the inner frame plate 180 along its outer contour. The fastening groove 160 is provided at the connection between the outer contour surface of the outer frame plate 170 and the upper end wall of the slot 140. That is, the fastening groove 160 is set as a notch located at the end edge of the upper end wall of the slot 140. This setting facilitates the processing and manufacturing of the fastening groove 160, reduces production costs, and after the buckle 102 is fastened to the fastening groove 160 with the above-described structure, the lower end of the buckle 102 is exposed. When it is necessary to detach the buckle 102 from the fastening groove 160, it is also convenient to directly apply force to the lower end of the buckle 102.

[0063] It is understood that the engaging groove 160 and the guide groove 150 may be connected or not connected (i.e., spaced apart). When the engaging groove 160 and the guide groove 150 are connected (not shown in the figure), as the latch 102 moves along the guide groove 150 until it reaches the engaging groove 160, the latch 102 is subject to the lateral restraint of the two side walls of the guide groove 150 throughout the process. This prevents the latch 102 from deviating from the predetermined path when it leaves the guide groove 150 but has not yet reached the engaging groove 160, thus ensuring accurate engagement. In this case, the bottom surface of the guide groove 150 may not be inclined, and the engaging groove 160 and the guide groove 150 may be configured as a through groove with a protrusion in the middle. The upper side of the protrusion is the guide groove 150, and the lower side is the engaging groove 160, so that the through groove provides guidance and engagement fixation for the latch 102. When the engaging groove 160 and the guide groove 150 are not connected (refer to...), Figure 7 When (as shown), the connection strength between the buckle 102 and the fastening groove 160 can be increased, preventing the buckle 102 from easily coming out of the fastening groove 160. In this case, the interval between the fastening groove 160 and the guide groove 150 should be reasonably set.

[0064] It should be further explained that, referring to Figure 2 , Figure 7 , Figure 8As shown, the outer frame plate 170 is provided with an inlet groove 111 and an outlet groove 112. Along the circumferential direction of the outer contour, the inlet groove 111 and the outlet groove 112 are located on both sides of the guide groove 150 and the fastening groove 160, respectively. The inlet groove 111 and the outlet groove 112 are both located at the upper end of the outer frame plate 170. The inlet groove 111 and the outlet groove 112 extend downward from the top of the outer frame plate 170 along the height direction of the first insulating frame 110, and the inlet groove 111 and the outlet groove 112 are respectively connected to the winding position 130, so that the winding can be introduced into the winding position 130 from the inlet groove 111 and led out from the outlet groove 112. The lead wire at the inlet groove 111 is the inlet wire 210, and the lead wire at the outlet groove 112 is the outlet wire 220. Both the inlet wire 210 and the outlet wire 220 are connected to the busbar 200. It is understandable that the winding is performed layer by layer along the winding end face of the winding section 190. After the winding assembly is completed, it has a certain height, which can also be understood as the thickness of the layers of the winding itself. Thus, there is a difference in height between the exit position 220 and the entry position 210 of the winding. Here, the winding end face of the winding section 190 can be understood as the upper end face of the winding position of the first insulating frame 110 and the lower end face of the winding position of the second insulating frame 120.

[0065] See Figure 7 , Figure 8 and Figure 9 As shown, specifically, the inlet slot 111 is located near the right side of the first insulating frame 110, and the outlet slot 112 is located near the left side of the first insulating frame 110. Figure 4 As shown, the left side wall of the inlet slot 111 is the first side wall 1111, and the right side wall of the outlet slot 112 is the second side wall 1121. The center point along the circumferential direction of the connection between the upper end face of the winding portion 190 and the outer frame plate 170 is the center point. The plane formed by this center point and the central axis of the stator insulation frame 100 is defined as the center plane. The distance between the first side wall 1111 and the center plane is the first distance L1, and the distance between the second side wall 1121 and the center plane is the second distance L2. L1 and L2 satisfy: L1 < L2, that is, the first distance L1 is less than the second distance L2. In other words, in the circumferential direction of the outer contour, the inlet slot 111 is closer to the upper end face of the winding portion 190 than the outlet slot 112, so that the inlet slot 111 can match the position of the inlet 210, and the outlet slot 112 can also match the position of the outlet 220, which is beneficial to improving the stability of the inlet 210 and the outlet 220.

[0066] It should be noted that one side of the upper end face of the winding portion 190 is connected to the inner contour surface of the outer frame plate 170. The connection extends circumferentially along the outer contour. The center point can also be understood as the midpoint of the circumferential width of the connection along the outer contour of the winding portion 190. Therefore, the plane passing through this center point and the central axis of the outer contour is defined as the center plane. The inlet groove 111 is closer to the center plane than the outlet groove 112.

[0067] See Figure 8 , Figure 10 and Figure 11 As shown, it can be understood that, in the axial direction of the stator insulation frame 100, the axial distance between the upper end face of the outer frame plate 170 of the first insulation frame 110 and the bottom surface of the inlet groove 111 is the first depth H1, and the axial distance between the upper end face of the outer frame plate 170 and the bottom surface of the outlet groove 112 is the second depth H2. The magnitudes of H1 and H2 satisfy: H1 > H2, that is, the depth of the inlet groove 111 is greater than the depth of the outlet groove 112, so that the inlet groove 111 can match the position of the inlet 210 in the height direction, and the outlet groove 112 can match the position of the outlet 220 in the height direction, which facilitates the inlet 210 to be introduced from the inlet groove 111 and the outlet 220 to be led out from the outlet groove 112.

[0068] Understandably, in both the circumferential and axial directions of the outer contour, the inlet slot 111 is closer to the upper end face of the winding section 190 than the outlet slot 112. The winding is introduced into the winding position 131 of the winding section 190 from the inlet slot 111. When the inlet 210 begins winding, it can be close to the upper end face of the first insulating frame 110, reducing the distance between the inlet 210 and the upper end face of the winding section 190, eliminating the need for the inlet 210 to pass through the inlet slot 111. After 1, it needs to extend a certain distance to reach the upper end face of the winding part 190, which helps to shorten the length of the incoming wire 210. After the winding group is completed, the outgoing wire 220 is located at the outermost layer of the winding group. That is, the outgoing wire 220 will be far away from the upper end face of the winding part 190 relative to the incoming wire 210, so that the outgoing wire groove 112 can be close to the position of the outgoing wire 220, reducing the distance of the outgoing wire 220 from the winding group to the outgoing wire groove 112, thereby shortening the length of the outgoing wire 220. It can be understood that the inlet wire 210 can be tightly attached to the inlet slot 111, and the outlet wire 220 can be tightly attached to the outlet slot 112, so that the inlet wire 210 and the outlet wire 220 are respectively tightly fitted with the first insulating frame 110, reducing the space where the lead wires are prone to loosening. After the inlet wire 210 and the outlet wire 220 are led out, they are directly connected to the busbar 200, which facilitates accurate and reliable positioning with the busbar 200. The connection structure is stable and reliable, reducing the possibility of the inlet wire 210 or the outlet wire 220 becoming loose, thereby effectively reducing the defect rate, improving product reliability, and increasing production efficiency, which is conducive to reducing production costs.

[0069] It should be noted that the first insulating frame 110 and the second insulating frame 120 are connected to the stator core 103, with the first insulating frame 110 and the second insulating frame 120 located on both sides of the teeth of the stator core 103, respectively. After the winding assembly is completed, the first insulating frame 110 is connected to the busbar 200 by a snap-fit ​​method, fixing the busbar 200 to the stator core 103. Then, the inlet wire 210 and outlet wire 220 of the winding assembly are welded to the terminals 207 on the busbar 200, respectively. With the inlet wire 210 and outlet wire 220 reliably positioned, it is beneficial to quickly weld and fix, resulting in higher efficiency.

[0070] See Figure 11 As shown, both the inlet groove 111 and the outlet groove 112 are U-shaped grooves with their openings facing upwards. The inlet groove 111 and the outlet groove 112 are located on opposite sides of the center plane. The first distance L1 between the left side wall of the inlet groove 111 and the center plane, and the second distance L2 between the right side wall of the outlet groove 112 and the center plane can be set according to the actual application requirements of the product. In the embodiment, the ratio of the first distance L1 to the second distance L2 satisfies: 0.5 < L1 / L2 < 1. It can be understood that the above setting can ensure that the inlet groove 111 is closer to the upper end face of the winding part 190 in the horizontal direction than the outlet groove 112, and the positional distribution of the inlet groove 111 and the outlet groove 112 along the circumferential direction of the outer contour is more reasonable.

[0071] See Figure 12 As shown, the circumferential width of the winding portion 190 along its outer contour is L0, and L1 and L0 satisfy: L1 = L0 / 2, that is, the distance between the left side wall of the inlet groove 111 and the center surface is equal to half the circumferential width of the upper end surface of the winding portion 190. After the wire 210 is introduced into the winding portion 190 through the inlet groove 111, it is close to the upper end surface of the winding portion 190, thereby effectively reducing the distance between the wire 210 and the upper end surface of the winding portion 190 from the inlet groove 111 and avoiding unnecessary lead wire length.

[0072] Understandably, when 0.5 < L1 / L2 < 1 and L1 = L0 / 2, the inlet slot 111 is close to the upper end face of the winding section 190, and the outlet slot 112 is far from the upper end face of the winding section 190. When winding begins, the inlet 210 is close to the upper end face of the winding section 190. After the winding is completed, the outlet 220 is close to the outlet slot 112, effectively shortening the length of the inlet 210 and the outlet 220. This allows the inlet 210 and the outlet 220 to fit tightly with the first insulating frame 110, reducing the space where the lead wires may loosen. This is more conducive to achieving accurate and reliable positioning with the busbar 200, reducing the possibility of the inlet 210 or the outlet 220 loosening, and improving product reliability.

[0073] It should be noted that, in some embodiments, reference is made to... Figure 2 , Figure 9 As shown, a first partition wall exists between the guide groove 150 and the inlet groove 111, and a second partition wall exists between the guide groove 150 and the outlet groove 112. The width of the first partition wall is W5, and the width of the second partition wall is W6. The widths W5 and W6 of the first and second partition walls satisfy: W5 > W6. The reason for this arrangement is that the inlet wire 210 and the outlet wire 220 need to be connected to the terminals 207 of the busbar 200, respectively. The terminals 207 are configured as hooks. This arrangement facilitates the inlet wire 210 and the outlet wire 220 to correspond to the hooks of the busbar 200, thus avoiding interference between the busbar 200 and the stator insulation frame 100.

[0074] It should be noted that the specific dimensions of the first horizontal distance L1, the second horizontal distance L2, and the width L0 of the upper end face of the winding part 190 can be set according to the actual application requirements of different motors. For example, L1 can be 3mm, L2 can be 5mm, and L0 can be 6mm. No further limitations are made here.

[0075] See Figure 11 As shown in the embodiment, the ratio of the first depth H1 and the second depth H2 satisfies: 0.4 < H2 / H1 < 0.8. It can be understood that the bottom surface of the inlet groove 111 is closer to the upper end surface of the winding part 190. The inlet wire 210 is introduced into the upper end surface of the winding part 190, and the winding starts from the bottom layer. After completion, the outlet wire 220 is located at the outermost layer of the winding group, that is, the outlet wire 220 is at the highest position of the winding group. In this way, in the height direction, the inlet groove 111 is closer to the upper end surface of the winding part 190 than the outlet groove 112, and the positional distribution of the inlet groove 111 and the outlet groove 112 along the height direction is more reasonable.

[0076] See Figure 12 and Figure 14 As shown, it should be noted that a first winding groove 113 is provided on the upper end face of the winding portion 190, and a second winding groove 121 is provided on the lower end face of the winding portion 190. The first winding groove 113 is arranged radially along the first insulating frame 110, and the second winding groove 121 is arranged radially along the second insulating frame 120. The first winding groove 113 and the second winding groove 121 are used to position the winding, ensuring the winding is properly positioned and preventing the winding from shifting and becoming tangled.

[0077] Understandably, referring to Figure 10 , Figure 12As shown, the first winding groove 113 has a first end near the inlet groove 111 and a second end near the outlet groove 112. The distance between the first end and the inner side of the outer frame plate 170 is W3, and the distance between the second end and the inner side of the outer frame plate 170 is W4, wherein W3 and W4 satisfy: W3 > W4. This facilitates the introduction of the inlet wire 210 from the inlet groove 111 and the exit wire 220 from the outlet groove 112, reducing the possibility of loosening of the inlet wire 210 and the outlet wire 220, and improving product reliability.

[0078] See Figure 11 and Figure 13 As shown in the embodiment, the axial distance between the upper end of the outer frame plate 170 of the first insulating frame 110 and the upper end face of the winding part 190 is H3, and the wire diameter of the winding is d. The difference between H3 and H1 satisfies: 0.5d < H3 - H1 < d. H3 - H1 can be understood as the distance between the bottom surface of the inlet groove 111 and the upper end face of the winding part 190. This distance is less than the wire diameter of the winding but greater than half of the wire diameter. In this way, after the inlet wire 210 is introduced from the inlet groove 111, it can directly fit into the first winding groove 113, and the winding operation can begin. There is no need to bend the inlet wire 210 or other operations to introduce the inlet wire 210 into the first winding groove 113. This helps to keep the position of the inlet wire 210 of the winding group in a straight state, so that the inlet wire 210 fits tightly into the inlet groove 111, the structure is more compact, the positioning effect is better, and the possibility of the inlet wire 210 becoming loose is further reduced, thus improving the reliability of the product.

[0079] It should be noted that, see Figure 6 As shown, the distance between the upper end of the outer frame plate 170 of the first insulating frame 110 and the upper end face of the slot 140 is H0. During assembly, the upper end face of the slot 140 is in contact with the stator core 103. H0 satisfies H2 < H1 < H3 < H0. It can be understood that the inlet wire 210 is closer to the stator core 103 than the outlet wire 220, which meets the electrical safety performance requirements and makes the structure more reasonable. In the embodiment, the specific dimensional parameters of the first depth H1, the second depth H2, the third depth H3, the distance H0 between the upper end of the outer frame plate 170 of the first insulating frame 110 and the upper end face of the slot 140, and the wire diameter d can be set according to the actual application requirements of different motors, and will not be elaborated further.

[0080] See Figure 8 and Figure 14As shown, the radial cross-section of the first winding groove 113 and the second winding groove 121 along the outer contour is arc-shaped, which allows the first winding groove 113 and the second winding groove 121 to better match the winding wire. In addition, the diameter of the arc of the first winding groove 113 and the second winding groove 121 can match the wire diameter. For example, the diameter of the arc of the first winding groove 113 is greater than or equal to the wire diameter, so that the winding wire is reliably positioned and a better winding effect is guaranteed.

[0081] See Figure 8 , Figure 9 As shown, it can be understood that the first insulating frame 110 is inserted into the tooth position of the stator core 103, and the second insulating frame 120 is inserted into the corresponding tooth position. They are connected by the first insertion slot 114 and the second insertion slot 122 to form a slot 140. The side wall of the slot 140 is in close contact with the stator core 103 so that the winding assembly can be tightly wound on the tooth of the stator core 103 and the insulation between the stator core 103 and the winding assembly can be guaranteed.

[0082] It should be noted that the connection between the upper end wall of the slot 140 and the two side walls of the slot 140 along the circumferential direction of the outer contour, as well as the connection between the lower end wall of the slot 140 and the two side walls of the slot 140 along the circumferential direction of the outer contour, are all set as right-angle transitions. That is, the corners 115 set on the side walls of the slot 140 are not chamfered. Taking the first insulating frame 110 as an example, the right-angle corners 115 are more conducive to the cooperation with the stator core 103, which can make the side walls of the slot 140 fit more tightly with the teeth of the stator core 103, effectively improving the overall structural stability of the stator insulating frame 100 and the stator core 103.

[0083] See Figure 1 and Figure 12 As shown, it should be noted that the stator core 103 is annular, and the stator insulation frame 100 is distributed annularly at the tooth position of the stator core 103, so that the stator insulation frame 100 can surround the stator core 103. It can be understood that the first insulation frame 110 and the second insulation frame 120 have arc-shaped outer contour surfaces and arc-shaped inner contour surfaces. That is, the outer frame plate 170 and the inner frame plate 180 along the radial direction of the stator core 103 on the first insulation frame 110 and the second insulation frame 120 are both arc-shaped, and the arc of the outer contour and the arc of the inner contour are both coaxial with the stator core 103, so that the stator insulation frame 100 and the stator core 103 have better matching.

[0084] It should be noted that in some embodiments, the inlet slot 111 and the outlet slot 112 can be separately disposed at the upper and lower ends of the frame unit 101. Specifically, the inlet slot 111 is disposed on the upper outer frame plate 170 of the first insulating frame 110, and the outlet slot is disposed on the lower outer frame plate 170 of the second insulating frame 120. That is, the inlet wire 210 is introduced from the upper end of the first insulating frame 110, and the outlet wire 220 is led out from the lower end of the second insulating frame 120. Of course, the positions of the inlet slot 111 and the outlet slot 112 can be interchanged, so that the positions of the inlet wire 210 and the outlet wire 220 are swapped. The specific setting depends on the actual application requirements of the motor, which will not be elaborated here. Furthermore, when the inlet slot 111 is located at the upper end of the outer frame plate 170 of the first insulating frame 110, the axial distance between the upper end face of the outer frame plate 170 and the upper end face of the winding portion 190 is the third depth H3; when the inlet slot 111 is located at the lower end of the outer frame plate 170 of the second insulating frame 120, the axial distance between the lower end face of the outer frame plate 170 and the lower end face of the winding portion 190 is the third depth H3. The specific proportional relationship between H3, H0, and H1 can be found in [reference needed]. Figure 11 and Figure 13 As shown.

[0085] According to a second aspect embodiment of the present invention, the motor (not shown in the figures) includes the stator 1000 of the first aspect embodiment of the present invention. The stator 1000 includes a stator core 103 and a stator insulation frame 100 as shown in the above embodiment. The stator insulation frame 100 is connected to the stator core 103. The motor housing, rotor and other components are not shown in the figures. It is understood that multiple frame units 101 are arranged in a ring on the stator core 103, and then winding groups are wound on the frame units 101. Each winding group has an inlet wire 210 and an outlet wire 220. After the winding groups are completed, the busbar 200 is fastened to the first insulating frame 110 to fix the busbar 200 on the stator core 103. Then, the inlet wire 210 and outlet wire 220 on each first insulating frame 110 are respectively connected to the terminal block 207 of the busbar 200. In this embodiment, the terminal block 207 adopts a hook structure, and the inlet wire 210 and outlet wire 220 are respectively welded to the corresponding hooks. Thus, the inlet and outlet ends of each winding group are gathered together by the busbar 200 to form a stator assembly, which is more compact and reliable. It should be noted that the motor in this embodiment of the invention includes a DC motor and an AC motor.

[0086] According to the present invention, the motor has a guide groove 150 provided above the snap-fit ​​groove 160 of the frame unit 101, which facilitates the alignment of the snap-fit ​​102 with the snap-fit ​​groove 160, improves the assembly efficiency of the busbar 200 and the stator insulation frame 100, and correspondingly improves the manufacturing efficiency of the motor and reduces the production cost.

[0087] The electric power steering system (not shown in the figure) of the third aspect of the present invention includes the motor of the second aspect of the present invention.

[0088] It should be noted that the electric power steering (EPS) system of this invention is a power steering system that directly relies on an electric motor to provide auxiliary torque. The EPS mainly consists of a torque sensor, a vehicle speed sensor, a motor, a reduction gear, and an electronic control unit, wherein the motor is the same as that described in the above embodiments. Since the electric power steering system adopts all the technical solutions of the motor in the above embodiments, it possesses at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be elaborated further here.

[0089] The vehicle (not shown in the figure) according to the fourth aspect of the present invention includes the electric power steering system of the third aspect of the present invention. Since the vehicle adopts all the technical solutions of the electric power steering system of the above embodiments, it has at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be repeated here.

[0090] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.

Claims

1. A stator, characterized in that, include: The busbar is in the shape of a ring, with a buckle extending downwards at the lower end; A stator insulation frame is located below the busbar and is snapped and fixed to the busbar. The stator insulation frame includes multiple frame units arranged in a ring. Each frame unit includes an outer frame plate, an inner frame plate, and a winding portion located between the outer frame plate and the inner frame plate. The multiple outer frame plates form the outer contour of the stator insulation frame, and the multiple inner frame plates form the inner contour of the stator insulation frame. Wherein, the outer contour surface of the outer frame plate and the inner contour surface of the inner frame plate are concentric arc surfaces, the outer contour surface of the outer frame plate is provided with a fastening groove that cooperates with the buckle, and the outer contour surface of the outer frame plate is also provided with a guide groove, the guide groove being located above the fastening groove; The guide groove is disposed at the connection between the outer contour surface of the outer frame plate and the upper end surface of the outer frame plate. The bottom surface of the guide groove is configured as a first guide surface, which is inclined from top to bottom toward the radially outer side of the outer contour. The buckle includes a fixing part and a hook part. The fixing part is connected to the busbar. The hook part is connected to the fixing part and is used to hook and engage with the fastening groove. The lower end of the hook part is provided with an inclined second guide surface on the inner side of the radial direction of the outer contour. The inclination angle of the second guide surface relative to the axial direction of the outer contour is γ, and the inclination angle of the first guide surface relative to the axial direction of the outer contour is θ. The magnitudes of γ and θ satisfy: γ > θ. The fastening groove is connected to the guide groove, or the fastening groove and the guide groove are spaced apart.

2. The stator according to claim 1, characterized in that, The bottom surface of the guide groove is set as a plane, the cross section of the guide groove along the radial direction of the outer contour is triangular, the maximum thickness of the outer frame plate along the radial direction of the outer contour is S1, the height of the cross section of the guide groove along the radial direction of the outer contour is S2, and the inclination angle of the first guide surface relative to the axial direction of the outer contour is θ, the magnitude of θ satisfies: 0° < θ < arctan (S1 / S2).

3. The stator according to claim 1, characterized in that, The frame unit is provided with a slot for inserting the stator core. The slot passes through the outer frame plate, the winding part and the inner frame plate radially along the outer contour. The fastening groove is provided at the connection between the outer contour surface of the outer frame plate and the upper end wall of the slot.

4. The stator according to claim 3, characterized in that, The connection points between the upper end wall of the card slot and the two side walls of the card slot along the circumference of the outer contour, as well as the connection points between the lower end wall of the card slot and the two side walls of the card slot along the circumference of the outer contour, are all set as right-angle transitions.

5. The stator according to claim 3, characterized in that, The frame unit includes a first insulating frame and a second insulating frame located below the first insulating frame. The lower end of the first insulating frame is provided with a first insertion slot, and the upper end of the second insulating frame is provided with a second insertion slot that is inserted and fixed to the first insertion slot. The first insertion slot is located on one of the inner and outer sides of the lower edge of the first insulating frame, and the second insertion slot is located on the other of the inner and outer sides of the upper edge of the second insulating frame. The inner side is the side closest to the center of the slot, and the outer side is the side opposite to the center of the slot relative to the inner side. The axial height of the first insertion slot along the outer contour is E1, and the axial height of the second insertion slot along the outer contour is E2. E1 and E2 satisfy: E1=E2≥0.5mm.

6. The stator according to claim 1, characterized in that, The outer frame plate is provided with an inlet slot and an outlet slot. Along the circumference of the outer contour, the inlet slot and the outlet slot are located on both sides of the guide slot and the fastening slot, respectively. The inlet slot and the outlet slot are both located at the upper end of the outer frame plate, or one of the inlet slot and the outlet slot is located at the upper end of the outer frame plate and the other is located at the lower end of the outer frame plate.

7. An electric motor, characterized in that, Includes the stator as described in any one of claims 1 to 6.

8. An electric power steering system, characterized in that, Including the motor as described in claim 7.

9. A vehicle, characterized in that, Includes the electric power steering system as described in claim 8.

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