A stator, a rounding die and a rounding method

Abstract

The application provides a kind of stator, round forming die and round forming method, wherein the stator includes stator core, framework and stator winding, stator core is formed with multiple circumferential grooves;When the stator is roughly formed, multiple stator cores are arranged along the circumference and spliced together, and the circumferential grooves of multiple stator cores are sequentially communicated;When the stator is precisely formed, plastic sealing material is injected into the circumferential groove, which can tightly fix the stator core;The round forming process is simple and high in precision, solving the problems of complex round forming process, low precision and poor quality of the prior art stator;The round forming die includes a first die and a second die, and is arranged along the axial direction of the stator for axial positioning of the stator;The round forming die further includes a third die and a fourth die, and is arranged along the circumferential direction of the stator for radial fixation of the stator;The first die, the third die, the fourth die and the stator form a plastic sealing cavity, plastic sealing material is injected into the plastic sealing cavity to form a plastic sealing fastening hoop, and the stator is fixed, optimizing the round forming process of the stator.

Description

Technical Field

[0001] This invention belongs to the field of motor technology, and particularly relates to a stator, a rounding mold, and a rounding method. Background Technology

[0002] Modular stators are widely used due to their high material utilization, high winding efficiency, and low cost; however, the rounding process of modular stators is a technical bottleneck, and the quality of rounding directly affects motor performance. Current stator rounding processes involve splicing multiple stator cores into a circle and then placing fastening hoops on the outer periphery of the stator to make its structure compact. However, the tightness of the fastening hoops is difficult to control. If they are too loose, the stator's outer diameter will be too large, affecting subsequent assembly or injection molding of the entire machine; if they are too tight, the stator cores will be squeezed and deformed, forming a "flared mouth," which easily causes motor noise. Furthermore, the tooling is inconvenient to operate, and the stator is prone to springback after removal, resulting in low rounding accuracy and poor quality. Summary of the Invention

[0003] In view of this, the present invention provides a stator, a rounding mold, and a rounding method to solve the problems of complex rounding process, low precision, and poor quality of stator in the prior art.

[0004] This invention provides a stator, comprising a stator core, a frame embedded in the stator core, and a stator winding wound on the stator core. The stator core is provided in multiple configurations, and each stator core has a groove formed on its outer peripheral wall. The multiple stator cores are sequentially spliced ​​together circumferentially to form the stator, and the grooves of the multiple stator cores are sequentially connected. The outer peripheral wall of the stator is provided with a plastic-coated fastening clamp, which is injection molded into the groove of the stator core.

[0005] Alternatively, the groove may include a circumferential groove; the plastic-coated fastening hoop is disposed along the circumferential groove of the stator.

[0006] Further optionally, the circumferential groove includes a first circumferential groove and a second circumferential groove; the groove further includes an axial groove; the stator core includes a plurality of first stator cores and a plurality of second stator cores; the first circumferential groove and the axial groove are formed on the outer peripheral wall of the first stator core, and the first circumferential groove communicates with the axial groove; the second circumferential groove is formed on the outer peripheral wall of the second stator core;

[0007] Multiple first stator cores are spaced apart, and at least one second stator core is disposed between two adjacent first stator cores. The first circumferential groove and the second circumferential groove are connected.

[0008] Further optionally, along the axial direction of the first stator core, a plurality of first circumferential grooves are formed on the outer peripheral wall of the first stator core, and each first circumferential groove communicates with the axial groove.

[0009] Along the axial direction of the second stator core, a plurality of second circumferential grooves are formed on the outer peripheral wall of the second stator core; the number of the first circumferential grooves is the same as the number of the second circumferential grooves.

[0010] Optionally, the first stator core includes a first lamination unit, a second lamination unit, and a third lamination unit. The first lamination unit includes a1 first laminations A, the second lamination unit includes b first laminations B, and the third lamination unit includes a2 first laminations A. The first laminations A form a slot. The first lamination unit, the second lamination unit, and the third lamination unit surround the first circumferential groove, and the slots of the first lamination unit and the slots of the third lamination unit form the axial groove.

[0011] R1 and r1 satisfy R1 > r1, where R1 is the radius of the outer edge of the first lamination A and r1 is the radius of the outer edge of the first lamination B.

[0012] Further optionally, the second stator core includes a fourth lamination unit, a fifth lamination unit, and a sixth lamination unit, wherein the fourth lamination unit includes a1 second laminations A, the fifth lamination unit includes b second laminations B, and the sixth lamination unit includes a2 second laminations A; the fourth lamination unit, the fifth lamination unit, and the sixth lamination unit are arranged to form the second circumferential groove;

[0013] R2 and r2 satisfy R2 > r2, where R2 is the radius of the outer edge of the second lamination A and r2 is the radius of the outer edge of the second lamination B.

[0014] Further optionally, the number of the first stator cores is 2m, and the number of the second stator cores is 2m*n; when the stator is formed into a circle, four of the first stator cores are respectively set at the four quadrant points of the circle, and the four quadrants of the circle are centered on the center of the circle; every n second stator cores are sequentially spliced ​​and set between two adjacent first stator cores; where m≥2, n≥1.

[0015] The present invention also provides a stator forming mold according to any one of the preceding claims, wherein the stator forming process includes rough forming and fine forming, and the forming mold is a mold required for the fine forming of the stator; the forming mold includes a first mold and a second mold, wherein the first mold has a first base;

[0016] When the stator is precisely rounded, along the axial direction of the stator, the first base is disposed at one end of the stator, and the second mold is disposed at the other end of the stator for axial positioning of the stator.

[0017] Further optionally, a mounting hole is formed at the center of the stator; the first mold further includes an annular boss and a first positioning shaft disposed on the first base; the first positioning shaft is coaxially disposed with the annular boss, and the first positioning shaft is located inside the annular boss; a clearance groove is formed between the first positioning shaft and the annular boss;

[0018] When the stator is precisely rounded, the annular boss abuts against one end of the stator core, the first positioning shaft is disposed in the mounting hole, and one end of the skeleton is disposed in the clearance groove.

[0019] Further optionally, the first mold further includes a second positioning shaft formed on the first positioning shaft, the second positioning shaft being coaxial with the first positioning shaft;

[0020] The second mold has a positioning hole and a limiting ring, the positioning hole and the limiting ring are coaxially arranged, and the limiting ring is located radially outside the positioning hole;

[0021] When the stator is precisely rounded, the second mold abuts against the end of the first positioning shaft near the second positioning shaft, the positioning hole is sleeved on the outside of the second positioning shaft, and the end of the limiting ring abuts against the other end of the skeleton.

[0022] Further optionally, the limiting ring includes a first limiting ring and a second limiting ring, the first limiting ring and the second limiting ring are coaxially arranged, and the first limiting ring is located radially outside the second limiting ring; the skeleton forms an outer sidewall and an inner sidewall of the skeleton arranged radially opposite to each other along the skeleton.

[0023] When the stator is precisely rounded, the first limiting ring abuts against the outer wall of the frame, and the second limiting ring abuts against the inner wall of the frame.

[0024] Further optionally, the rounding mold also includes a third mold and a fourth mold, both of which are arc-shaped structures.

[0025] When the stator is precisely rounded, the third mold is fastened to one side of the stator along the circumference of the stator, and the fourth mold is fastened to the other side of the stator for radial fixation of the stator.

[0026] Further optionally, both the third mold and the fourth mold are semi-circular structures; both the third mold and the fourth mold include an arc-shaped plate, a first mounting ear and a second mounting ear; along the circumference of the arc-shaped plate, the first mounting ear is disposed at one end of the arc-shaped plate and forms a positioning groove; the second mounting ear is disposed at the other end of the arc-shaped plate and forms a positioning protrusion;

[0027] When the stator is precisely rounded, the positioning groove of the third mold and the positioning protrusion of the fourth mold cooperate, and the positioning protrusion of the third mold and the positioning groove of the fourth mold cooperate to achieve the positioning of the third mold and the fourth mold.

[0028] Alternatively, both the first mounting ear and the second mounting ear are formed with mold closing holes, which extend circumferentially along the arc-shaped plate and are used for connecting the third mold and the fourth mold.

[0029] Optionally, one end of the arc-shaped plate is formed with an arc-shaped boss, and the arc-shaped boss is coaxially arranged with the arc-shaped plate;

[0030] When the stator is precisely rounded, the arc-shaped boss abuts against the other end of the stator core, a first axial cavity is formed between the axial groove and the inner wall of the arc plate, and a first annular cavity is formed between the first circumferential groove and the second circumferential groove and the inner wall of the arc plate.

[0031] Further optionally, the inner sidewall of the arc-shaped plate is formed with an axial protrusion; when the stator is precisely rounded, a second axial cavity is formed between the axial protrusion and the axial groove.

[0032] Further optionally, a first annular groove is formed at the end of the annular boss away from the first base; when the stator is precisely rounded, a second annular cavity is formed between the first annular groove and the inner wall of the arc-shaped plate; and / or

[0033] A second annular groove and a feed inlet are formed between the arc-shaped boss and the inner wall of the arc-shaped plate, and the feed inlet is connected to the second annular groove; when the stator is precisely rounded, a third annular cavity is formed between the second annular groove and the end of the stator core.

[0034] The first annular cavity, the second annular cavity, the third annular cavity, the first axial cavity, and the second axial cavity are connected to form a plastic sealing cavity, and plastic sealing material is injected into the plastic sealing cavity to form a plastic-coated fastening band.

[0035] The present invention also provides a method for forming a circle according to the stator described above, the method comprising:

[0036] When the stator is roughly rounded, multiple stator cores are arranged and spliced ​​together along the circumference, and the circumferential grooves of the multiple stator cores are connected in sequence.

[0037] When the stator is precisely rounded, a molding compound is injected into the circumferential groove to secure the stator core.

[0038] Further, optionally, the circle-forming method further includes:

[0039] When the stator is precisely rounded, the stator that has been roughly rounded is placed on the first mold.

[0040] The third and fourth molds are fastened to the outer periphery of the stator;

[0041] The second mold is placed on the first mold.

[0042] Further, optionally, the circle-forming method further includes:

[0043] Injecting molding compound into the molding cavity forms a plastic-coated fastening clamp.

[0044] Compared with the prior art, the main advantages of the present invention are as follows:

[0045] (1) Grooves are formed on the outer peripheral wall of the stator core. Multiple stator cores are spliced ​​together to form a stator. The grooves of multiple stator cores are connected in sequence. Plastic sealant is injected into the grooves to form plastic-coated fastening hoops, which fasten the stator, ensure the roundness quality of the stator, and improve the stability of motor operation.

[0046] (2) Circumferential grooves are formed on the outer peripheral wall of the stator core. When the stator is rough-rounded, multiple stator cores are spliced ​​together and multiple circumferential grooves are connected in sequence. When the stator is fine-rounded, plastic sealant is injected into the circumferential grooves to tighten the stator core. The rounding process is simple, with high precision and stable quality. It does not affect the subsequent assembly of the whole machine. The motor noise is low. It solves the problems of complex rounding process, low precision and poor quality of stator in the existing technology.

[0047] (3) The first stator core is formed by stacking the first lamination A and the first lamination B and has a first circumferential groove and an axial groove. The first circumferential groove and the axial groove are connected. The second stator core is formed by stacking the second lamination A and the second lamination B and has a second circumferential groove. Then, when the stator is rounded, a plastic-coated fastening hoop is formed, so that the stator is dimensionally stable and not easily deformed.

[0048] (4) The rounding mold includes a first mold and a second mold, which are arranged along the axial direction of the stator and are used for axial positioning of the stator; the rounding mold also includes a third mold and a fourth mold, which are arranged along the circumference of the stator and are used for radial fixing of the stator; the first mold, the third mold, the fourth mold and the stator form a plastic sealing cavity, and the plastic sealing material is injected into the plastic sealing cavity to form a plastic-coated fastening hoop, which fixes the stator and makes the connection between the stator cores tight, thereby improving the connection strength between the stator cores, optimizing the rounding process of the stator, and the entire process does not require welding of the stator cores, thereby improving the rounding accuracy of the stator and ensuring the rounding quality of the stator. Attached Figure Description

[0049] To more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings in the following description are merely exemplary, and those skilled in the art can derive other embodiments based on the provided drawings without creative effort.

[0050] The structures, proportions, sizes, etc. illustrated in this specification are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed herein, and are not intended to limit the conditions under which the present invention can be implemented. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportions, or adjustments to the size, without affecting the effects and objectives that the present invention can produce, should still fall within the scope of the technical content disclosed in the present invention.

[0051] Figure 1a This is a schematic diagram of the structure of the first stator core embodiment provided by the present invention;

[0052] Figure 1b This is a schematic diagram of the structure of the first lamination A embodiment provided by the present invention;

[0053] Figure 1c This is a schematic diagram of the structure of the first lamination B embodiment provided by the present invention;

[0054] Figure 2a This is a schematic diagram of the structure of the second stator core embodiment provided by the present invention;

[0055] Figure 2b This is a schematic diagram of the structure of the second lamination A embodiment provided by the present invention;

[0056] Figure 2c This is a schematic diagram of the structure of the second lamination B embodiment provided by the present invention;

[0057] Figure 3a This is a schematic diagram of the structure of the first winding stator embodiment provided by the present invention;

[0058] Figure 3b This is a schematic diagram of the structure of the second winding stator embodiment provided by the present invention;

[0059] Figure 4a and Figure 4b This is a schematic diagram of an embodiment of the stator roughing process provided by the present invention;

[0060] Figure 5 A schematic diagram of the structure of the first mold embodiment provided by the present invention;

[0061] Figure 6a and Figure 6b This is a schematic diagram of the structure of the second mold embodiment provided by the present invention;

[0062] Figure 7 Schematic diagrams of the third and fourth mold embodiments provided by the present invention;

[0063] Figure 8a and Figure 8b This is a schematic diagram of an embodiment of the present invention in which a precision-formed circular stator and a circular forming mold (excluding a second mold) are assembled together;

[0064] Figure 9a and Figure 9b This is a schematic diagram of an embodiment of the present invention in which a precision-formed circular stator and a circular forming mold (including a second mold) are assembled together;

[0065] Figure 10 This is a schematic diagram of the structure of an embodiment of the closing of the third and fourth molds during stator precision rounding provided by the present invention;

[0066] Figure 11 This is a schematic diagram of the structure of an embodiment of the plastic-coated fastening hoop provided by the present invention;

[0067] Figure 12 This is a schematic diagram of the stator structure after precision rounding provided by the present invention;

[0068] Figure 13 This is a schematic flowchart of an embodiment of the stator circularization method provided by the present invention;

[0069] In the picture:

[0070] 11-First stator core; 111-First circumferential slot; 112-Axial slot; 113-First lamination A; 1131-Slot opening; 114-First lamination B; 12-Second stator core; 121-Second circumferential slot; 122-Second lamination A; 123-Second lamination B; 13-Mounting hole; 141-Rivet; 142-Rivet slot; 15-Frame; 151-Outer wall of frame; 152-Inner wall of frame; 16-Stator winding;

[0071] 21-First mold; 211-First base; 212-Annular boss; 213-First annular groove; 214-First positioning shaft; 215-Second positioning shaft; 216-Allowing groove;

[0072] 22-Second mold; 221-Positioning hole; 223-First limiting ring; 224-Second limiting ring; 225-Allowing space;

[0073] 231-Third mold; 232-Fourth mold; 233-Arc plate; 2331-Arc boss; 2332-Axial protrusion; 234-First mounting ear; 2341-Positioning groove; 235-Second mounting ear; 2351-Positioning protrusion; 236-Mold closing hole; 237-Second annular groove; 238-Feed inlet;

[0074] 3-Plastic-coated fastening hoop; 311-First annular reinforcement A; 312-First annular reinforcement B; 32-Second annular reinforcement; 33-Third annular reinforcement; 341-First axial reinforcement A; 342-First axial reinforcement B; 351-Second axial reinforcement A; 352-Second axial reinforcement B; 36-Axial pre-reserved groove;

[0075] 411-First annular cavity A; 412-First annular cavity B; 42-Second annular cavity; 43-Third annular cavity; 441-First axial cavity A; 442-First axial cavity B; 451-Second axial cavity A; 452-Second axial cavity B. Detailed Implementation

[0076] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0077] The terminology used in the embodiments of this invention is for the purpose of describing particular embodiments only and is not intended to limit the invention. The singular forms “a,” “the,” and “the” used in the embodiments of this invention and the appended claims are also intended to include the plural forms, unless the context clearly indicates otherwise. “Multiple” generally includes at least two, but does not exclude the inclusion of at least one.

[0078] It should be understood that the term "and / or" used in this article is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. Additionally, the character " / " in this article generally indicates that the preceding and following related objects have an "or" relationship.

[0079] It should also be noted that the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a product or system comprising a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a product or system. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the product or system that includes said element.

[0080] The existing stator rounding process involves splicing multiple stator cores into a circle and then placing fastening hoops on the outer periphery of the stator to make the stator structure compact. However, the tightness of the fastening hoops is not easy to control. If they are too loose, the outer diameter of the stator will be too large, affecting the subsequent assembly or injection molding of the whole machine. If they are too tight, the stator cores will be squeezed and deformed, forming a "flared mouth", which can easily cause motor noise. In addition, the tooling is inconvenient to operate, and the stator is prone to springback after removal. The rounding accuracy and quality of the stator are low.

[0081] This invention creatively provides a stator, including a stator core, a frame, and stator windings. The stator core has grooves and includes multiple grooves. Multiple stator cores are arranged circumferentially and spliced ​​together to form the stator, and the grooves of the multiple stator cores are sequentially connected. The outer peripheral wall of the stator is provided with a plastic-coated fastening hoop, which is injection molded into the grooves of the stator core and can fasten the stator core. The rounding process is simple and produces good quality, improving the stability of motor operation, not affecting the subsequent assembly of the whole machine, and the motor noise is low.

[0082] stator core

[0083] like Figure 4a and Figure 4b As shown, the stator core includes multiple stator cores, and each stator core has a groove formed on its outer peripheral wall. The stator rounding process includes rough rounding and fine rounding. During the rough rounding of the stator, multiple stator cores are arranged and spliced ​​together along the circumference, and the circumferential grooves of the multiple stator cores are connected in sequence. During the fine rounding of the stator, a molding compound is injected into the grooves to tighten the stator core.

[0084] Specifically, the stator core is I-shaped and includes a yoke. Along the circumference of the yoke of the stator core, one end of the yoke forms a rivet 141 and the other end forms a rivet groove 142. When the stator is rough-rounded, in two adjacent stator cores, the rivet 141 of one stator core is embedded in the rivet groove 142 of the other stator core, thereby connecting the two adjacent stator cores. Similarly, multiple stator cores are arranged and connected along the circumference to achieve rough rounding of the stator. To reduce the difficulty of splicing production, the fit between the rivet 141 and the rivet groove 142 is a conventional clearance fit. After rough rounding, the outer diameter 2R of the stator even exceeds the upper limit of the tolerance, resulting in a loose structure. If the fit between the rivet 141 and the rivet groove 142 is tight, it will lead to splicing difficulties, and forced assembly will cause core deformation.

[0085] <First Stator Core>

[0086] The groove includes a circumferential groove and an axial groove, the circumferential groove including a first circumferential groove 111 and a second circumferential groove 121; for example Figure 1a , Figure 1b and Figure 1c As shown, the stator core includes a plurality of first stator cores 11 and a plurality of second stator cores 12; the outer peripheral wall of the first stator core 11 is formed with a first circumferential groove 111 and an axial groove 112, and the first circumferential groove 111 and the axial groove 112 are connected.

[0087] Furthermore, along the axial direction of the first stator core 11, a plurality of first circumferential grooves 111 are formed on the outer peripheral wall of the first stator core 11, and each first circumferential groove 111 is connected to the axial groove 112.

[0088] The first stator core 11 includes a first lamination unit, a second lamination unit, and a third lamination unit. The first lamination unit is formed by stacking a1 first laminations A 113 together, the second lamination unit is formed by stacking b first laminations B 114 together, and the third lamination unit is formed by stacking a2 first laminations A 113 together; satisfying R1 > r1, where R1 is the radius of the outer edge of the first lamination A 113 and r1 is the radius of the outer edge of the first lamination B 114; the first lamination A 113 forms a slot 1131, which extends along the axial direction of the first lamination A 113; the first lamination unit, the second lamination unit, and the third lamination unit surround a first circumferential groove 111, and the slots 1131 of the first lamination unit and the slots 1131 of the third lamination unit form an axial groove 112; specifically, the slot 1131 has a trapezoidal structure, and the number of slots 1131 can be set according to actual needs;

[0089] When stacking the first laminations A 113 and B 114, firstly, stack the first laminations A 113 in quantity a1 together, then stack the first laminations B 114 in quantity b together, and then stack the first laminations A 113 in quantity a2 together. Thus, the first laminations A 113 in quantity a1, the first laminations B 114 in quantity b, and the first laminations A 113 in quantity a2 form the first circumferential groove 111. The groove openings 1131 of the first laminations A 113 in quantity a1 and the groove openings 1131 of the first laminations A 113 in quantity a2 form the axial groove 112. The values ​​of a1, b, and a2 can be set according to actual needs, and thus the number of the first circumferential groove 111 and the axial groove 112 can be set according to actual needs.

[0090] The first stator core 11 includes a plurality of first circumferential grooves 111 and a plurality of axial grooves 112, wherein the plurality of first circumferential grooves 111 are arranged along the axial direction of the first stator core 11; in this embodiment, the first stator core 11 includes two first circumferential grooves 111 and one axial groove 112.

[0091] <Second Stator Core>

[0092] like Figure 2a , Figure 2b and Figure 2c As shown, a second circumferential groove 121 is formed on the outer peripheral wall of the second stator core 12; along the axial direction of the second stator core 12, a plurality of second circumferential grooves 121 are formed on the outer peripheral wall of the second stator core 12; the number of first circumferential grooves 111 is the same as the number of second circumferential grooves 121.

[0093] When the stator is roughly round, multiple first stator cores 11 are spaced apart, and at least one second stator core 12 is provided between two adjacent first stator cores 11. The first circumferential groove 111 and the second circumferential groove 121 are connected; a mounting hole 13 is formed at the center of the stator.

[0094] Furthermore, the second stator core 12 includes a fourth lamination unit, a fifth lamination unit, and a sixth lamination unit. The fourth lamination unit is formed by stacking a1 second laminations A 122 together, the fifth lamination unit is formed by stacking b second laminations B 123 together, and the sixth lamination unit is formed by stacking a2 second laminations A 122 together; satisfying R2 > r2, where R2 is the radius of the outer edge of the second lamination A 122, and r2 is the radius of the outer edge of the second lamination B 123; the structure of the second lamination B 123 is the same as the structure of the first lamination B 114; the second lamination A 122 does not form a slot; the fourth lamination unit, the fifth lamination unit, and the sixth lamination unit surround a second circumferential slot 121;

[0095] When stacking the second lamination A 122 and the second lamination B 123, first stack the second laminations A 122 in quantity a1 together, then stack the second laminations B 123 in quantity b together, and then stack the second laminations A 122 in quantity a2 together. The second laminations A 122 in quantity a1, the second laminations B 123 in quantity b, and the second laminations A 122 in quantity a2 form the second circumferential groove 121. The values ​​of a1, b, and a2 can be set according to actual needs, and thus the second circumferential groove 121 can be set according to actual needs.

[0096] The second stator core 12 includes a plurality of second circumferential grooves 121, which are arranged along the axial direction of the second stator core 12; in this embodiment, the second stator core 12 includes two second circumferential grooves 121.

[0097] like Figure 3a and Figure 3b As shown, both the frame 15 and the stator winding 16 include multiple components. Each frame 15 is embedded on the corresponding first stator core 11, and each stator winding 16 is wound on the corresponding first stator core 11, thus forming a first wound stator. Each frame 15 is embedded on the corresponding second stator core 12, and each stator winding 16 is wound on the corresponding second stator core 12, thus forming a second wound stator.

[0098] The number of first stator cores 11 is 2m, and the number of second stator cores 12 is 2m*n. When the stator is formed into a circle, four of the first stator cores 11 are respectively set at the four quadrant points of the circle, with the center of the circle as the center point. Every n second stator cores 12 are sequentially spliced ​​and set between two adjacent first stator cores 11. Wherein, m≥2, n≥1; preferably, m=2, n=1.

[0099] In this embodiment, the stator is a 12-slot stator, n=2, and there are 8 second stator cores 12. Every two second stator cores 12 are sequentially spliced ​​and arranged between two adjacent first stator cores 11. The first stator core 11 is A, the second stator core 12 is B, and the winding sequence of the 12-slot stator is ABBABBABBABB; if it is an 8-slot stator, it is ABABABAB; the first circumferential slot 111, the second circumferential slot 121 and the axial slot 112 are interwoven on the outer peripheral wall of the stator.

[0100] Round mold

[0101] The stator rounding process includes rough rounding and fine rounding. The rounding mold is the mold required for the fine rounding of the stator. The rounding mold includes the first mold 21, the second mold 22, the third mold 231 and the fourth mold 232.

[0102] <First mold and second mold>

[0103] like Figure 5 , Figure 6a and Figure 6b As shown, the first mold 21 has a first base 211; when the stator is precisely rounded, the first base 211 is set at one end of the stator along the axial direction of the stator, and the second mold 22 is set at the other end of the stator for axial positioning of the stator; specifically, the first base 211 and the second mold 22 are both plate-shaped structures.

[0104] Furthermore, the first mold 21 also includes an annular boss 212 and a first positioning shaft 214. Both the annular boss 212 and the first positioning shaft 214 are disposed on the first base 211. The first positioning shaft 214 is coaxially disposed with the annular boss 212 and is located inside the annular boss 212. A clearance groove 216 is formed between the first positioning shaft 214 and the annular boss 212. The outer diameter of the first positioning shaft 214 is the same as the inner diameter of the mounting hole 13 when the stator is roughened into a circle.

[0105] When the stator is precisely round, the annular boss 212 abuts against one end of the stator core to axially limit the stator. The first positioning shaft 214 is set in the mounting hole 13 to radially limit the stator. One end of the skeleton 15 is set in the clearance groove 216.

[0106] In addition, the first mold 21 also includes a second positioning shaft 215, which is formed on the first positioning shaft 214 and is coaxial with the first positioning shaft 214;

[0107] The second mold 22 has a positioning hole 221 and a limiting ring. The positioning hole 221 and the limiting ring are coaxially arranged, and the limiting ring is located on the radial outer side of the positioning hole 221. The inner diameter of the positioning hole 221 is the same as the outer diameter of the second positioning shaft 215.

[0108] When the stator is precisely rounded, the second mold 22 abuts against the end of the first positioning shaft 214 near the second positioning shaft 215, the positioning hole 221 is sleeved on the outside of the second positioning shaft 215, and the end of the limiting ring abuts against the other end of the frame 15 to axially limit the stator.

[0109] Furthermore, the limiting ring includes a first limiting ring 223 and a second limiting ring 224, the first limiting ring 223 and the second limiting ring 224 are coaxially arranged, and the first limiting ring 223 is located radially outside the second limiting ring 224; the skeleton 15 forms a skeleton outer sidewall 151 and a skeleton inner sidewall 152 arranged radially opposite to each other along the skeleton 15.

[0110] When the stator is precisely rounded, the first limiting ring 223 abuts against the outer wall 151 of the frame, and the second limiting ring 224 abuts against the inner wall 152 of the frame.

[0111] To address the issue of poor injection molding quality caused by an unreasonable design of the feed inlet 238, this embodiment proposes that the second mold 22 form a clearance section 225 to avoid the feed inlet 238, thereby ensuring smooth feeding and injection molding quality.

[0112] <Third and Fourth Molds>

[0113] like Figure 7 As shown, both the third mold 231 and the fourth mold 232 have an overall arc-shaped structure;

[0114] When the stator is precisely rounded, along the circumference of the stator, the third mold 231 is fastened to one side of the stator, and the fourth mold 232 is fastened to the other side of the stator for radial fixation of the stator.

[0115] Furthermore, the third mold 231 and the fourth mold 232 have the same structure and are both semi-circular in shape. The third mold includes an arc plate 233, a first mounting ear 234 and a second mounting ear 235. Along the circumference of the arc plate 233, the first mounting ear 234 is located at one end of the arc plate 233 and forms a positioning groove 2341, and the second mounting ear 235 is located at the other end of the arc plate 233 and forms a positioning protrusion 2351. The first mounting ear 234 and the second mounting ear 235 extend radially along the arc plate 233.

[0116] When the stator is precisely rounded, the positioning groove 2341 of the third mold 231 engages with the positioning protrusion 2351 of the fourth mold 232, and the positioning protrusion 2351 of the third mold 231 engages with the positioning groove 2341 of the fourth mold 232, thereby achieving the positioning of the third mold 231 and the fourth mold 232, and making the third mold 231 and the fourth mold 232 form a ring structure.

[0117] To address the unreliable connection between the third mold 231 and the fourth mold 232, this embodiment proposes that both the first mounting ear 234 and the second mounting ear 235 have mold closing holes 236. The mold closing holes 236 extend circumferentially along the arc plate 233 and are used for connecting the third mold 231 and the fourth mold 232. Specifically, there are multiple mold closing holes 236. When connecting the third mold 231 and the fourth mold 232, the mold closing holes 236 of the third mold 231 correspond to the mold closing holes 236 of the fourth mold 232, and the third mold 231 and the fourth mold 232 are fastened with bolts or other tooling.

[0118] To address the problem of loose connections between stator cores, this embodiment proposes that: ① an arc-shaped boss 2331 is formed at one end of the arc-shaped plate 233, and the arc-shaped boss 2331 is coaxially arranged with the arc-shaped plate 233;

[0119] like Figure 8a , Figure 8b , Figure 9a , Figure 9b and Figure 10 As shown, when the stator is precisely rounded, the arc-shaped boss 2331 abuts against the other end of the stator core, a first axial cavity is formed between the axial groove 112 and the inner wall of the arc plate 233, and a first annular cavity is formed between the first circumferential groove 111 and the second circumferential groove 121 and the inner wall of the arc plate 233.

[0120] ② An axial protrusion 2332 is formed on the inner sidewall of the arc-shaped plate 233; specifically, an axial protrusion 2332 is formed in the middle of the arc-shaped plate 233 along the circumference of the arc-shaped plate 233; the arc-shaped plate 233 also forms an arc-shaped boss 2331, which is coaxial with the arc-shaped plate 233; the cross-sections of the axial protrusion 2332 and the arc-shaped boss 2331 can be any reasonable shape, such as a cuboid and a triangle;

[0121] When the stator is precisely rounded, a second axial cavity is formed between the axial protrusion 2332 and the axial groove 112.

[0122] ③ A first annular groove 213 is formed at the end of the annular boss 212 away from the first base 211; the diameter of the side wall of the first annular groove 213 is the same as the outer diameter of the stator when it is rounded.

[0123] When the stator is precisely rounded, a second annular cavity 42 is formed between the first annular groove 213 and the inner wall of the arc plate 233; the feed port 238 is connected to the second annular cavity 42 and is used for the formation of the plastic-coated fastening hoop 3;

[0124] ④ A second annular groove 237 and a feed inlet 238 are formed between the arc-shaped boss 2331 and the inner wall of the arc-shaped plate 233, and the feed inlet 238 is connected to the second annular groove 237.

[0125] When the stator is precisely rounded, a third annular cavity 43 is formed between the second annular groove 237 and the end of the stator core;

[0126] like Figure 11 and Figure 12 As shown, the first annular cavity, the second annular cavity 42, the third annular cavity 43, the first axial cavity and the second axial cavity are connected to form a plastic sealing cavity. Plastic sealing material is injected into the plastic sealing cavity to form a plastic-coated fastening clamp 3, which fixes the stator and makes the connection between the stator cores tight, so that the stator dimensions are stable and not easily deformed, improving the connection strength between the stator cores, optimizing the stator rounding process, and eliminating the need for welding the stator cores throughout the process, thus improving the rounding accuracy of the stator and ensuring the rounding quality of the stator.

[0127] Methods for forming a circle

[0128] This embodiment also provides a method for forming a circle based on the stator described above, the method comprising:

[0129] S1. When the stator is roughly rounded, multiple stator cores are arranged and spliced ​​together along the circumference, and then the circumferential slots of the multiple stator cores are connected in sequence.

[0130] S2. When the stator is precisely rounded, inject plastic sealant into the circumferential groove to tighten the stator core.

[0131] Furthermore, such as Figure 13 As shown, S2 includes:

[0132] S21. Set the rounded stator onto the first mold 21;

[0133] S22. Fasten the third mold 231 and the fourth mold 232 onto the outer periphery of the stator;

[0134] S23. If the second mold 22 is set on the first mold 21, then the four molds will enclose the stator that has been roughened into a circle.

[0135] An annular boss 212 abuts against one end of the stator core to axially limit the stator; a first positioning shaft 214 is set in the mounting hole 13 to radially limit the stator; a third mold 231 and a fourth mold 232 are fastened to the outer periphery of the stator and apply pressure to the stator; a second mold 22 abuts against the end of the first positioning shaft 214 near the second positioning shaft 215, a positioning hole 221 is sleeved on the outside of the second positioning shaft 215, and the end of the limiting ring abuts against the other end of the frame 15 to axially limit the stator;

[0136] After applying appropriate pressure to the mold, the stator, which is restricted in all directions, will be compressed into a compact structure in the high-precision mold. The inner and outer diameters and height dimensions will be limited within the mold forming dimensions. As long as the mold precision is sufficient, the stator that is roughly rounded can be finely rounded into a qualified stator.

[0137] In this example, the first stator core 11 includes stator core A1, stator core A2, stator core A3 and stator core A4;

[0138] When the stator is rounded, stator cores A1, A2, A3, and A4 are respectively positioned at the 12 o'clock, 3 o'clock, 6 o'clock, and 9 o'clock positions during roughing. The first mounting ear 234 of the third mold 231 is positioned at the 12 o'clock position during roughing, and the second mounting ear 235 of the third mold 231 is positioned at the 6 o'clock position during roughing. A first axial cavity A 441 is formed between the axial groove 112 of stator core A1 and the inner wall of the arc plate 233, and a first axial cavity B 442 is formed between the axial groove 112 of stator core A3 and the inner wall of the arc plate 233.

[0139] The axial protrusion 2332 of the third mold 231 is located at the 3 o'clock position of the coarse circle, and a second axial cavity A 451 is formed between the axial protrusion 2332 of the third mold 231 and the axial groove 112 of the stator core A2; the axial protrusion 2332 of the fourth mold 232 is located at the 9 o'clock position of the coarse circle, and a second axial cavity B 452 is formed between the axial protrusion 2332 of the fourth mold 232 and the axial groove 112 of the stator core A4.

[0140] Along the axial direction of the first stator core 11, the first stator core 11 forms a first circumferential groove A and a first circumferential groove B; along the axial direction of the second stator core 12, the second stator core 12 forms a second circumferential groove A and a second circumferential groove B; a first annular cavity A 411 is formed between the first circumferential groove A and the second circumferential groove A and the inner wall of the arc plate 233; a first annular cavity B 412 is formed between the first circumferential groove B and the second circumferential groove B and the inner wall of the arc plate 233.

[0141] A second annular cavity 42 is formed between the first annular groove 213 and the inner wall of the arc plate 233; a third annular cavity 43 is formed between the second annular groove 237 and the end of the stator core.

[0142] After the mold is closed and pressure is applied, the stator in the mold cavity not only achieves the required dimensional accuracy, but also has the first axial cavity A 441, the first axial cavity B 442, the second axial cavity A 451, the second axial cavity B 452, the first annular cavity A 411, the first annular cavity B 412, the second annular cavity 42 and the third annular cavity 43 crisscrossed.

[0143] Furthermore, S2 also includes:

[0144] S24. Injecting molding compound into the molding cavity forms the plastic-coated fastening hoop 3;

[0145] Specifically, the molding compound forms a first annular rib A 311 in the first annular cavity A 411, a first annular rib B 312 in the first annular cavity B 412, a second annular rib 32 in the second annular cavity 42, a third annular rib 33 in the third annular cavity 43, a first axial rib A 341 in the first axial cavity A 441, and a first axial rib B 342 in the first axial cavity B 442; the molding compound forms a second axial rib A 351 in the second axial cavity A 451, and a second axial rib B 352 in the second axial cavity B 452. The first annular ribs A 311, B 312, 32, 33, A 341, B 342, A 351, and B 352 interweave to form the plastic-coated fastening band 3.

[0146] In addition, methods for forming a circle also include:

[0147] S3, Demolding; that is, removing the stator from the mold. At this time, the plastic-coated fastening hoop 3 wraps around the outer periphery of the stator, preventing the stator size from springing back in all directions, and restricting the rounded stator within the required appropriate size. The outer axial side view of the stator after rounding is not a smooth cylindrical surface, but still retains the reserved groove on the plastic-coated fastening hoop 3, which is to increase the contact area with the plastic sealant and improve the structural strength when the stator is plastic-sealed in the future. Specifically, the plastic-coated fastening hoop 3 has axial reserved grooves 36 on the outer walls of the annular ribs and axial ribs.

[0148] In summary, the plastic-coated fastening clamp 3 secures the stator and tightly connects the stator cores, ensuring dimensional stability and preventing deformation of the stator. It also improves the connection strength between the stator cores, optimizes the stator rounding process, eliminates the need for welding the stator cores, improves the rounding accuracy of the stator, and guarantees the rounding quality of the stator.

[0149] Exemplary embodiments of this disclosure have been specifically shown and described above. It should be understood that this disclosure is not limited to the detailed structures, arrangements, or implementations described herein; rather, this disclosure is intended to cover various modifications and equivalent arrangements contained within the spirit and scope of the appended claims.

Claims

1. A stator, comprising a stator core, a frame embedded in the stator core, and a stator winding wound on the stator core, characterized in that, The stator core is provided in multiple ways, and each stator core has a groove formed on its outer peripheral wall; the multiple stator cores are spliced ​​together in sequence along the circumference to form a stator, and the grooves of the multiple stator cores are connected in sequence; the outer peripheral wall of the stator is provided with a plastic-coated fastening hoop, which is formed in the groove of the stator core by injection molding.

2. The stator according to claim 1, characterized in that, The groove includes a circumferential groove; the plastic-coated fastening hoop is provided along the circumferential groove of the stator.

3. The stator according to claim 2, characterized in that, The circumferential groove includes a first circumferential groove and a second circumferential groove; the groove also includes an axial groove; the stator core includes a plurality of first stator cores and a plurality of second stator cores; the first circumferential groove and the axial groove are formed on the outer peripheral wall of the first stator core, and the first circumferential groove is connected to the axial groove; the second circumferential groove is formed on the outer peripheral wall of the second stator core; Multiple first stator cores are spaced apart, and at least one second stator core is disposed between two adjacent first stator cores. The first circumferential groove and the second circumferential groove are connected.

4. The stator according to claim 3, characterized in that, Along the axial direction of the first stator core, a plurality of first circumferential grooves are formed on the outer peripheral wall of the first stator core, and each first circumferential groove is connected to the axial groove. Along the axial direction of the second stator core, a plurality of second circumferential grooves are formed on the outer peripheral wall of the second stator core; the number of the first circumferential grooves is the same as the number of the second circumferential grooves.

5. The stator according to claim 3, characterized in that, The first stator core includes a first lamination unit, a second lamination unit, and a third lamination unit. The first lamination unit includes a1 first laminations A, the second lamination unit includes b first laminations B, and the third lamination unit includes a2 first laminations A. The first laminations A form a slot. The first lamination unit, the second lamination unit, and the third lamination unit surround the first circumferential groove, and the slots of the first lamination unit and the slots of the third lamination unit form the axial groove. The radius R1 of the outer edge of the first lamination A and the radius r1 of the outer edge of the first lamination B satisfy: R1 > r1.

6. The stator according to claim 5, characterized in that, The second stator core includes a fourth lamination unit, a fifth lamination unit, and a sixth lamination unit. The fourth lamination unit includes a1 second laminations A, the fifth lamination unit includes b second laminations B, and the sixth lamination unit includes a2 second laminations A. The fourth lamination unit, the fifth lamination unit, and the sixth lamination unit are arranged to form the second circumferential groove. The radius R2 of the outer edge of the second lamination A and the radius r2 of the outer edge of the second lamination B satisfy: R2 > r2.

7. The stator according to any one of claims 3-6, characterized in that, The number of first stator cores is 2m, and the number of second stator cores is 2m*n. When the stator is formed into a circle, four of the first stator cores are respectively set at the four quadrant points of the circle, with the center of the circle as the center point. Every n second stator cores are sequentially spliced ​​and set between two adjacent first stator cores. Wherein, m≥2, n≥1.

8. A stator forming die according to any one of claims 3-6, characterized in that, The stator rounding process includes rough rounding and fine rounding, and the rounding mold is the mold required for the fine rounding of the stator; the rounding mold includes a first mold and a second mold, and the first mold has a first base; When the stator is precisely rounded, along the axial direction of the stator, the first base is disposed at one end of the stator, and the second mold is disposed at the other end of the stator for axial positioning of the stator.

9. The stator forming die according to claim 8, characterized in that, A mounting hole is formed at the center of the stator; the first mold also includes an annular boss and a first positioning shaft disposed on the first base; the first positioning shaft is coaxially disposed with the annular boss, and the first positioning shaft is located inside the annular boss; a clearance groove is formed between the first positioning shaft and the annular boss. When the stator is precisely rounded, the annular boss abuts against one end of the stator core, the first positioning shaft is disposed in the mounting hole, and one end of the skeleton is disposed in the clearance groove.

10. The stator forming die according to claim 9, characterized in that, The first mold further includes a second positioning shaft formed on the first positioning shaft, the second positioning shaft being coaxial with the first positioning shaft; The second mold has a positioning hole and a limiting ring, the positioning hole and the limiting ring are coaxially arranged, and the limiting ring is located on the radial outside of the positioning hole; When the stator is precisely rounded, the second mold abuts against the end of the first positioning shaft near the second positioning shaft, the positioning hole is sleeved on the outside of the second positioning shaft, and the end of the limiting ring abuts against the other end of the skeleton.

11. The stator forming die according to claim 10, characterized in that, The limiting ring includes a first limiting ring and a second limiting ring, which are coaxially arranged and located radially outside the second limiting ring along the first limiting ring; the skeleton forms an outer sidewall and an inner sidewall of the skeleton that are radially opposite to each other along the skeleton. When the stator is precisely rounded, the first limiting ring abuts against the outer wall of the frame, and the second limiting ring abuts against the inner wall of the frame.

12. The stator forming die according to claim 9, characterized in that, The circular forming mold also includes a third mold and a fourth mold, both of which are arc-shaped structures. When the stator is precisely rounded, the third mold is fastened to one side of the stator along the circumference of the stator, and the fourth mold is fastened to the other side of the stator for radial fixation of the stator.

13. The stator forming die according to claim 12, characterized in that, Both the third and fourth molds are semi-circular in shape. Each mold includes an arc-shaped plate, a first mounting ear, and a second mounting ear. Along the circumference of the arc-shaped plate, the first mounting ear is located at one end of the arc-shaped plate and has a positioning groove. The second mounting ear is located at the other end of the arc-shaped plate and has a positioning protrusion. When the stator is precisely rounded, the positioning groove of the third mold and the positioning protrusion of the fourth mold cooperate, and the positioning protrusion of the third mold and the positioning groove of the fourth mold cooperate to achieve the positioning of the third mold and the fourth mold.

14. The stator forming die according to claim 13, characterized in that, Both the first and second mounting ears have mold closing holes that extend circumferentially along the arc-shaped plate and are used for connecting the third and fourth molds.

15. The stator forming die according to claim 13, characterized in that, An arc-shaped boss is formed at one end of the arc-shaped plate, and the arc-shaped boss is coaxially arranged with the arc-shaped plate; When the stator is precisely rounded, the arc-shaped boss abuts against the other end of the stator core, a first axial cavity is formed between the axial groove and the inner wall of the arc plate, and a first annular cavity is formed between the first circumferential groove and the second circumferential groove and the inner wall of the arc plate.

16. The stator forming die according to claim 15, characterized in that, The inner wall of the arc-shaped plate has an axial protrusion; when the stator is precisely rounded, a second axial cavity is formed between the axial protrusion and the axial groove.

17. The stator forming die according to claim 16, characterized in that, The annular boss has a first annular groove at the end away from the first base; when the stator is precisely rounded, a second annular cavity is formed between the first annular groove and the inner wall of the arc-shaped plate; and / or, A second annular groove and a feed inlet are formed between the arc-shaped boss and the inner wall of the arc-shaped plate, and the feed inlet is connected to the second annular groove; when the stator is precisely rounded, a third annular cavity is formed between the second annular groove and the end of the stator core. The first annular cavity, the second annular cavity, the third annular cavity, the first axial cavity, and the second axial cavity are connected to form a plastic sealing cavity, and plastic sealing material is injected into the plastic sealing cavity to form a plastic-coated fastening band.

18. A method for forming a circle in a stator according to claim 17, characterized in that, The method for forming a circle includes: When the stator is roughly rounded, multiple stator cores are arranged and spliced ​​together along the circumference, and the circumferential grooves of the multiple stator cores are connected in sequence. When the stator is precisely rounded, a molding compound is injected into the circumferential groove to secure the stator core.

19. A method for forming a circle in a stator according to claim 18, characterized in that, The method for forming a circle also includes: When the stator is precisely rounded, the stator that has been roughly rounded is placed on the first mold. The third and fourth molds are fastened to the outer periphery of the stator; The second mold is placed on the first mold.

20. The method for forming a circle in a stator according to claim 19, characterized in that, The method for forming a circle also includes: Injecting molding compound into the molding cavity forms a plastic-coated fastening clamp.

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