Articulated plug-in stator assembly and assembly method thereof, motor, and air conditioner

Abstract

The present invention provides an articulated plug-in stator assembly and an assembly method thereof, a motor, and an air conditioner. The articulated plug-in stator assembly includes a plurality of core segments and coils. The plurality of core segments are articulated and plug-in to form a stator core. Each core segment is provided with an insulating frame. The coils are wound around the teeth of each core segment using a concentrated winding method and are located on the side of the insulating frame away from the core segment. The coils include winding segments corresponding to the teeth of the corresponding core segments and wire cross sections connecting different core segments within the same phase. The wire cross sections and winding segments within the same phase are continuously formed by the same coil. The wire cross section of one phase of the three-phase coil is located at the first end of the stator core, and the wire cross sections of the remaining two phase coils are located at the second end of the stator core. The present invention reduces the manufacturing cost of the motor, improves the degree of production automation, and improves the assembly efficiency of the stator assembly, saving time.

Description

Technical Field

[0001] The present invention belongs to the technical field of motor design, and in particular relates to an articulated plug-in stator assembly and an assembly method thereof, a motor, and an air conditioner. Background Art

[0002] Articulated stator cores are mostly made by stacking and forming individual core segments separately, and then assembling adjacent core segments into one by means of an articulated structure along the axial direction of the core. Corresponding to this structure, each core segment has piercing terminals passing through both axial ends thereof. The piercing terminals on the corresponding core segments are electrically connected according to wiring rules through wires independent of the coils on each core segment. However, this wiring and wire-passing method is time-consuming and has a low degree of production automation. At the same time, the piercing terminals set separately for each core segment are expensive, resulting in high manufacturing costs for the entire stator assembly and even the motor. Summary of the Invention

[0003] Therefore, the present invention provides an articulated plug-in stator assembly and its assembly method, motor, and air conditioner, which can solve the technical problems in the prior art that the wiring of each coil of the articulated plug-in stator assembly adopts a wiring method of piercing terminals, which is time-consuming, has a low degree of production automation, and has a high manufacturing cost.

[0004] In order to solve the above problems, the present invention provides an articulated and plug-in stator assembly, comprising a plurality of core segments and coils, wherein the plurality of core segments are formed into a circle by articulating and plugging, and an insulating frame is provided on each core segment. The coil is wound around the teeth of each core segment in a concentrated winding manner and is located on the side of the insulating frame away from the core segment. The coil is divided into three phases, and the coil includes winding segments corresponding to the teeth of the corresponding core segments and cross-line segments connecting different core segments in the same phase. The cross-line segments and the winding segments in the same phase are continuously formed by the same coil. The cross-line segments of one phase of the three-phase coils are located at the first end of the stator core, and the cross-line segments of the remaining two phases of the coils are located at the second end of the stator core.

[0005] In some embodiments, the three-phase coils are respectively the first phase, the second phase and the third phase, wherein the coils corresponding to the first phase and the second phase are simultaneously located at one end of the stator core, and the depth of the end wire groove of the insulating skeleton corresponding to the first phase is greater than the depth of the end wire groove of the insulating skeleton corresponding to the second phase.

[0006] In some embodiments, the three-phase coils are respectively the first phase, the second phase and the third phase, wherein each of the coils further has an input line segment and an output line segment that are continuous with the winding segment and the passing line segment, and the input line segment and the output line segment of the coils corresponding to the first phase, the second phase and the third phase are respectively located at one end of the stator core, the passing line segment of the coils corresponding to the first phase and the second phase are respectively located at one end of the stator core, and the passing line segment of the coil corresponding to the third phase is located at the other end of the stator core.

[0007] In some embodiments, the number of turns of the winding segments wound on the teeth of any one of the core segments corresponding to the third phase is one turn more than the number of turns of the winding segments wound on the teeth of the remaining core segments corresponding to the third phase, and the number of turns of the winding segments wound on the teeth of the remaining core segments in the third phase is equal to the number of turns of the winding segments wound on the teeth of the core segments corresponding to the first phase and the second phase respectively.

[0008] In some embodiments, the three-phase coils are respectively the first phase, the second phase and the third phase, wherein each of the coils further has an input line segment and an output line segment continuous with the winding segment and the passing line segment, the input line segments of the coils corresponding to the first phase, the second phase and the third phase are respectively located at one end of the stator core, the output line segments of the coils corresponding to the first phase, the second phase and the third phase are respectively located at the other end of the stator core, the passing line segments of the coils corresponding to the first phase and the second phase are respectively located at one end of the stator core, and the passing line segments of the coils corresponding to the third phase are located at the other end of the stator core, and the number of turns of the winding segments of the coils of each phase are equal.

[0009] In some embodiments, the circumferential first side of the core split has a hinge protrusion and the circumferential second side has a hinge groove, wherein the hinge groove is a necked groove, and the hinge protrusion of one of the two adjacent core splits can be hinged to the hinge groove of the other one in a manner to prevent it from falling out.

[0010] The present invention also provides a method for assembling the above-mentioned hinged plug-in stator assembly, comprising the following steps:

[0011] Assembling the respective core segments included in each phase, and assembling the insulating frame onto each of the core segments;

[0012] The coils are formed by winding the teeth of the iron core splits of the same phase, and the wire segments of the coils are located between two adjacent iron core splits in the same phase, forming three same-phase split components respectively;

[0013] The three same-phase split assemblies are respectively a first split assembly, a second split assembly, and a third split assembly, and the first split assembly and the second split assembly are inserted along the axial direction of the stator core to form a two-phase assembly, wherein the first split assembly and the second split assembly respectively have a line segment located at the first end of the stator core;

[0014] The third split component and the two-phase component are inserted along the axial direction of the stator core to form the articulated plug-in stator component, wherein the third split component has a line segment located at the second end of the stator core.

[0015] The present invention also provides a motor comprising the above-mentioned articulated plug-in stator assembly.

[0016] The present invention also provides an air conditioner comprising the above-mentioned motor.

[0017] The present invention provides an articulated plug-in stator assembly and its assembly method, motor, and air conditioner. In the articulated plug-in stator assembly, there is no need to set puncture terminals as in the prior art to achieve wire connection between the tooth portions of each core segment under the same phase, thereby reducing the manufacturing cost of the motor, improving the degree of production automation, and increasing the assembly efficiency of the stator assembly, which is more time-saving. More importantly, since the wire segments of each phase in this technical solution are respectively arranged at the first end and the second end of the corresponding stator core, the wire segments will not interfere with the axial insertion of the core segments of each phase after winding. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is a schematic diagram of the unfolded structure of an articulated plug-in stator assembly according to one embodiment of the present invention, showing that the outgoing and incoming segments of each phase coil are both located at the first end of the stator core (in the unfolded state);

[0019] Figure 2 This is a schematic diagram of the unfolded structure of the articulated plug-in stator assembly according to another embodiment of the present invention, showing that the incoming wire segments of each phase coil are all located at the first end of the stator core, while the outgoing wire segments are all located at the second end of the stator core (in the unfolded state);

[0020] Figure 3 for Figure 1 Schematic diagram of the structure of the stator core (in the circular state, projected along the axial direction);

[0021] Figure 4 for Figure 3 Schematic diagram of the structure of the split iron core;

[0022] Figure 5 for Figure 1Schematic diagram of the assembly state of the second split component (V phase) being inserted into the first split component (U phase) along the axial direction of the stator core from the first end to the second end (illustrated in an expanded state, but actually inserted in a circular state);

[0023] Figure 6 for Figure 1 The third split component (W phase) is connected to the stator core from the second end to the first end along the axial direction. Figure 5 Schematic diagram of the assembly state of the two-phase components assembled in the middle (illustrated in the unfolded state, but actually inserted in the circular state);

[0024] Figure 7 This is a schematic diagram of an articulated plug-in stator assembly assembled using the method of the present invention (shown in an unfolded state, but actually inserted in a circular state).

[0025] The reference numerals indicate:

[0026] 1. Split core; 11. Articulated protrusion; 12. Articulated groove; 2. Coil; 21. Wire section; 22. Inlet section; 23. Outlet section; 3. Insulation frame; 31. End wire groove. DETAILED DESCRIPTION

[0027] See also Figures 1 to 7 As shown, according to an embodiment of the present invention, an articulated plug-in stator assembly is provided, comprising a plurality of core segments 1 and coils 2. The plurality of core segments 1 are formed into a circle by articulating and plugging, forming a stator core. An insulating frame 3 is provided on each core segment 1. The coils 2 are wound around the teeth of each core segment 1 in a concentrated winding manner and are located on the side of the insulating frame 3 away from the core segment 1. The coils 2 are divided into three phases (specifically, Figure 1The U / V / W three-phase shown in the figure) is a three-phase coil 2, which includes winding segments corresponding to the teeth of the corresponding core segments 1 and wire segments 21 connected between different core segments 1 in the same phase. The wire segments 21 and the winding segments in the same phase are continuously formed by the same coil. The wire segments 21 of one phase of the three-phase coil 2 are located at the first end of the stator core, and the wire segments 21 of the remaining two-phase coils 2 are located at the second end of the stator core. It should be emphasized that the aforementioned winding segments and wire segments 21 are all different segments of one or a strand of enameled wire, which are continuous and do not require other switching components for switching. In this technical solution, the wire connection between the teeth of each core split 1 under the same phase can be achieved without setting the piercing terminal in the prior art in the articulated plug-in stator assembly, which reduces the manufacturing cost of the motor, improves the degree of production automation, and improves the assembly efficiency of the stator assembly and saves time. More importantly, since the wire segments 21 of each phase in this technical solution are respectively arranged at the first end and the second end of the corresponding stator core, the wire segments 21 will not interfere with the axial insertion of the core split 1 of each phase after winding.

[0028] In a specific embodiment, see Figure 1 or Figure 2 As shown, the three-phase coils are the first phase, the second phase, and the third phase, respectively. The coils 2 corresponding to the first and second phases are located at one end of the stator core, and the depth of the end wire-embedded groove 31 of the insulating frame 3 corresponding to the first phase is greater than the depth of the end wire-embedded groove 31 of the insulating frame 3 corresponding to the second phase. The aforementioned first phase, second phase, and third phase can each correspond to one of the three phases U / V / W. In this technical solution, by providing end wire-embedded grooves 31 of different depths at the ends of different corresponding insulating frames 3, the wire segments 21 at the same end (also referred to as the same side) can be arranged in layers in the axial direction after the stator assembly is assembled, resulting in a more reasonable layout.

[0029] like Figure 1 As shown, in one embodiment, each coil 2 also has an incoming line segment 22 and an outgoing line segment 23 that are continuous with the winding segment and the passing line segment 21. The incoming line segment 22 and the outgoing line segment 23 of the coils 2 corresponding to the first phase, the second phase, and the third phase are all located at one end of the stator core. The passing line segment 21 of the coils 2 corresponding to the first phase and the second phase are all located at one end of the stator core. The passing line segment 21 of the coil 2 corresponding to the third phase is located at the other end of the stator core. This technical solution arranges the incoming line segment 22 and the outgoing line segment 23 of each coil 2 at the first end of the stator core, which is beneficial for the lead-out and summary connection of the external power line. However, in this embodiment, since the passing line segment 21 corresponding to the coil 2 of the third phase and the passing line segments 21 corresponding to the coils 2 of the other two phases are located at different ends of the stator core, the coil 2 of the third phase is located at the same end as shown in FIG. Figure 1The winding portion on the tooth portion of the core split W1 shown enters from the top and exits from the bottom, and the winding on this tooth portion is half a turn less. The winding portion on the tooth portion of the core split W3 enters from the bottom and exits from the top, and the winding on this tooth portion is also half a turn less. In this way, in order to make the magnetic flux of each phase symmetrical, preferably, the number of turns of the winding segment wound on the tooth portion of any third corresponding core split 1 is one turn more than the number of turns of the winding segment wound on the tooth portion of the third corresponding remaining core split 1, and the number of turns of the winding segment wound on the tooth portion of the remaining core split 1 in the third phase is equal to the number of turns of the winding segment wound on the tooth portion of the core split 1 corresponding to the first phase and the second phase respectively.

[0030] like Figure 2 As shown, another feasible implementation method is shown, the first phase, the second phase and the third phase corresponding to the coil 2 each have an incoming wire segment 22 are all at one end of the stator core, the first phase, the second phase and the third phase corresponding to the coil 2 each have an outgoing wire segment 23 are all at the other end of the stator core, the first phase and the second phase corresponding to the coil 2 each have a through wire segment 21 at one end of the stator core, the third phase corresponding to the coil 2 has a through wire segment 21 at the other end of the stator core, the number of turns of the winding segments of the coil 2 of each phase are all equal, that is, in this technical solution, Figure 1 The difference from the technical solution shown is that the input segment 22 and the output segment 23 of each coil in the present application are respectively located at the first end and the second end of the stator core, and the three-phase magnetic flux formed by this structure is symmetrical. Therefore, the number of turns of the winding portion wound on each tooth portion in each phase can be equal.

[0031] See also Figure 3 and Figure 4 As shown, in some embodiments, the first circumferential side of the core split 1 has a hinge protrusion 11 and the second circumferential side has a hinge groove 12, wherein the hinge groove 12 is a necked groove, and the hinge protrusion 11 of one of the two adjacent core splits 1 can be hinged to the hinge groove 12 of the other to prevent it from falling out. The aforementioned hinge protrusion 11 has a necked connection portion corresponding to the necked position of the hinge groove 12. During the specific design, the maximum size L of the protruding part of the hinge protrusion 11 is designed to be larger than the maximum size L1 of the necked connection portion to prevent the hinge protrusion 11 from falling out after being connected to the hinge groove 12. This anti-slip hinge structure has the characteristic of more reliable connection. After connection, the stator assembly does not need to be welded after being rounded.

[0032] It should be noted that the number of core segments 1 in each phase should be at least two. In some embodiments, the rounded stator assembly can have 9 or 12 slots. Regardless of the number of slots, the ratio of the number of line segments corresponding to the first end and the second end of the stator core is 2:1.

[0033] See also Figures 5 to 7As shown, according to an embodiment of the present invention, there is also provided a method for assembling the above-mentioned hinged plug-in stator assembly, comprising the following steps:

[0034] Assemble the respective core segments 1 included in each phase, and assemble the insulating frame 3 onto each core segment 1. It is understood that the respective core segments 1 under each of the three phases and the insulating frame 3 thereon should then be placed in corresponding fixtures (or fixed at corresponding positions) according to the positions of the stator core in a circle.

[0035] The teeth of the core segments 1 of the same phase are wound to form coils 2, and the wire segments 21 of the coils 2 are located between two adjacent core segments 1 in the same phase, forming three same-phase segment components.

[0036] The three same-phase split components are respectively the first split component, the second split component and the third split component. The first split component and the second split component are inserted along the axial direction of the stator core to form a two-phase component. At this time, the position of the first split component can be fixed, and the second split component is inserted along the axial direction of the stator core close to the first split component (such as Figure 5 As shown, the first split assembly is specifically composed of U1 / U2 / U3, and the second split assembly is specifically composed of V1 / V2 / / V3). During this process, the line segments 21 of the first split assembly and the second split assembly should be located at the first end of the stator core; then, the third split assembly and the two-phase assembly are inserted along the axial direction of the stator core (as shown in FIG. Figure 6 As shown, the third split component is specifically composed of W1 / W2 / W3) to form an articulated plug-in stator component (such as Figure 7 As shown), the third split component has a line segment 21 located at the second end of the stator core.

[0037] In this technical solution, by corresponding each of the wire segments 21 to the different ends of the stator core, the axial insertion of the stator core is achieved without physical interference, thereby eliminating the need for puncturing terminals for connection, saving steps and costs, improving the degree of production automation, and thereby improving assembly efficiency.

[0038] According to an embodiment of the present invention, there is further provided a motor comprising the above-mentioned articulated plug-in stator assembly.

[0039] According to an embodiment of the present invention, there is also provided an air conditioner comprising the above-mentioned motor.

[0040] It is easy for those skilled in the art to understand that, under the premise of no conflict, the advantageous technical features of the above-mentioned methods can be freely combined and superimposed.

[0041] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the present invention. The above are merely preferred embodiments of the present invention. It should be noted that those skilled in the art may make various improvements and variations without departing from the technical principles of the present invention, and such improvements and variations shall also be considered within the scope of protection of the present invention.

Claims

1. An assembly method for an articulated plug-in stator assembly, wherein the articulated plug-in stator assembly comprises a plurality of core segments (1) and coils (2), wherein the plurality of core segments (1) are formed into a circle by articulated plug-in method to form a stator core, wherein each core segment (1) is provided with an insulating frame (3), wherein the coils (2) are wound around the teeth of each core segment (1) in a concentrated winding manner and are located on a side of the insulating frame (3) away from the core segment (1), wherein the coils (2) are divided into three phases, wherein the coils (2) comprise winding segments corresponding to the teeth of the corresponding core segments (1) and cross-line segments (21) connected between different core segments (1) in the same phase, wherein the cross-line segments (21) and the winding segments in the same phase are continuously formed by the same coil, wherein the cross-line segment (21) of one phase of the three-phase coils (2) is located at the first end of the stator core, and the coils (2) of the remaining two phases are located at the first end of the stator core. The line segment (21) is located at the second end of the stator core; the assembly method comprises the following steps: Assembling the respective iron core segments (1) included in each phase, and assembling the insulating frame (3) onto each of the iron core segments (1); The coil (2) is formed by winding the teeth of the iron core splits (1) of the same phase, and the wire section (21) of the coil (2) is located between two adjacent iron core splits (1) in the same phase, forming three same-phase split components respectively; The three same-phase split components are respectively a first split component, a second split component, and a third split component. The first split component and the second split component are inserted along the axial direction of the stator core to form a two-phase component, wherein the first split component and the second split component respectively have a line segment (21) located at the first end of the stator core; The third split component and the two-phase component are inserted along the axial direction of the stator core to form the articulated plug-in stator component, wherein the third split component has a line segment (21) located at the second end of the stator core.

2. The assembly method according to claim 1, wherein: The three-phase coils are respectively the first phase, the second phase and the third phase, wherein the coils (2) corresponding to the first phase and the second phase are both located at one end of the stator core, and the depth of the end wire-embedded groove (31) of the insulating frame (3) corresponding to the first phase is greater than the depth of the end wire-embedded groove (31) of the insulating frame (3) corresponding to the second phase.

3. The assembly method according to claim 1, wherein: The three-phase coils are respectively the first phase, the second phase and the third phase, wherein each of the coils (2) further has an incoming wire segment (22) and an outgoing wire segment (23) that are continuous with the winding segment and the passing wire segment (21), and the incoming wire segment (22) and the outgoing wire segment (23) of the coils (2) corresponding to the first phase, the second phase and the third phase are both located at one end of the stator core, the passing wire segment (21) of the coils (2) corresponding to the first phase and the second phase are located at one end of the stator core, and the passing wire segment (21) of the coil (2) corresponding to the third phase is located at the other end of the stator core.

4. The assembly method according to claim 3, characterized in that: The number of turns of the winding segments wound on the teeth of any one of the core segments (1) corresponding to the third phase is one turn more than the number of turns of the winding segments wound on the teeth of the remaining core segments (1) corresponding to the third phase, and the number of turns of the winding segments wound on the teeth of the remaining core segments (1) in the third phase is equal to the number of turns of the winding segments wound on the teeth of the core segments (1) corresponding to the first phase and the second phase respectively.

5. The assembly method according to claim 1, characterized in that: The three-phase coils are respectively the first phase, the second phase and the third phase, wherein each of the coils (2) further has an incoming wire segment (22) and an outgoing wire segment (23) which are continuous with the winding segment and the passing wire segment (21); the incoming wire segment (22) of the coils (2) corresponding to the first phase, the second phase and the third phase is located at one end of the stator core; the outgoing wire segment (23) of the coils (2) corresponding to the first phase, the second phase and the third phase is located at the other end of the stator core; the passing wire segment (21) of the coils (2) corresponding to the first phase and the second phase is located at one end of the stator core; the passing wire segment (21) of the coils (2) corresponding to the third phase is located at the other end of the stator core; the number of turns of the winding segments of the coils (2) of each phase is equal.

6. The assembly method according to claim 1, characterized in that: The first circumferential side of the core split (1) has a hinge protrusion (11), and the second circumferential side has a hinge groove (12), wherein the hinge groove (12) is a constricted groove, and the hinge protrusion (11) of one of the two adjacent core splits (1) can be hinged in the hinge groove (12) of the other in a manner that prevents it from coming out.

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