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

Abstract

Embodiments of the present application provide a stator assembly, a motor structure, an electric power steering system and a vehicle, wherein the stator assembly comprises: a stator core comprising a plurality of stator teeth, the stator teeth being wound with stator windings; an insulation frame provided at both ends of the stator teeth in the axial direction of the stator core, the insulation frame comprising a first baffle provided at the radially inner side of the stator core; and an insulation sheet provided on each stator tooth in the circumferential direction of the stator core and on at least one side of the stator windings; wherein the circumferential ends of the first baffle are respectively provided with a first protrusion and a second protrusion, the radial positions of the first protrusion and the second protrusion do not overlap, and there is a circumferential gap between adjacent first protrusions and second protrusions. In the technical solution of the present application, after the plurality of stator windings are wound on the stator teeth, the insulation sheet placed between the stator windings will be blocked by the first protrusion and the second protrusion in an interleaved manner, thereby achieving the effect of preventing sliding.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of electric machines, in particular to a stator assembly, an electric machine structure, an electric power steering system and a vehicle. BACKGROUND

[0002] At present, in order to realize the insulation of the slot, the existing electric machine needs insulation paper, which is placed between the windings. When the electric machine is running, vibration usually occurs, which causes the insulation paper to slide into the air gap between the stator and the rotor. SUMMARY

[0003] The present application aims to at least solve one of the problems in the prior art or related art.

[0004] Therefore, the embodiments of the first aspect of the present application provide a stator assembly.

[0005] The embodiments of the second aspect of the present application provide an electric machine structure.

[0006] The embodiments of the third aspect of the present application provide an electric power steering system.

[0007] The embodiments of the fourth aspect of the present application provide a vehicle.

[0008] In order to achieve the above-mentioned purpose, the embodiments of the first aspect of the present application provide a stator assembly, comprising: a stator core, the stator core comprising a plurality of stator teeth, each stator tooth being wound with a stator winding; an insulation frame provided at both ends of the stator teeth along the axial direction of the stator core, the insulation frame comprising a first baffle provided on the radially inner side of the stator core; an insulation sheet provided on at least one side of the stator winding of each stator tooth along the circumferential direction of the stator core; wherein the circumferential ends of the first baffle are respectively provided with a first protrusion and a second protrusion, the radial position of the first protrusion and the radial position of at least part of the second protrusion do not overlap, and in the two adjacent first baffles, the first protrusion of one of the first baffles is arranged adjacent to the second protrusion of the other first baffle, and there is a circumferential gap between the adjacent first protrusion and the second protrusion.

[0009] The stator assembly provided by the embodiment of the present application comprises a stator core, an insulating frame, an insulating sheet and a stator winding, wherein the stator core, as a main electromagnetic structure, comprises stator teeth, the number of the stator teeth is multiple, and the stator winding is provided with winding support, facilitating subsequent generation of a magnetic field, thereby driving the rotation of a rotor structure. Specifically, in order to reduce direct contact between the stator winding and the stator core and reduce the possibility of short-circuiting and burning of the motor due to accidental damage to the stator winding, the insulating frame is further arranged between the stator teeth and the stator winding, and under the action of the insulating frame, the electrical contact between the stator teeth and the stator winding can be effectively insulated, so that even if the outer skin of the stator winding is damaged, the stator winding cannot directly contact the stator teeth, thereby ensuring the safety of the stator assembly during installation and the overall use safety of the motor structure.

[0010] In the present scheme, the insulating sheet is further arranged between the adjacent two stator windings, that is, at least one side of the stator winding on each stator tooth along the circumferential direction of the stator core, and under the action of the insulating sheet, the stator winding can be effectively electrically insulated, thereby ensuring the safety of the motor during use. It can be understood that the insulating sheet needs to insulate the stator winding, and the position thereof is between the adjacent two stator windings. For the stator winding, due to the difference in the radius, the size of the radially outer side and the radially inner side of the stator winding will also be different, generally large on the outside and small on the inside. At this time, in order to prevent the insulating sheet from being stable during the operation of the motor, ensure that the position thereof is stable between the windings, reduce the possibility of slipping inward into the air gap between the stator and the rotor, and achieve the effect of stabilizing the insulation, staggered protrusions, that is, a first protrusion and a second protrusion, are arranged on the radially inner side of the insulating frame, that is, on both ends of the first baffle, and the radial positions of the first protrusion and the second protrusion at least partially do not overlap, that is, the radius range in which the first protrusion is located and the radius range in which the second protrusion is located do not completely coincide in the radial direction of the stator core, and there is a circumferential gap and a radial gap between the first protrusion and the second protrusion. After the multiple stator windings are wound on the stator teeth, the insulating sheet placed between the stator windings is blocked by the first protrusion and the second protrusion, thereby achieving the effect of preventing slipping.

[0011] It can be understood that the insulating sheet can be electrically insulating paper, including but not limited to cellulose paper, polyamide fiber paper, polyester non-woven fabric and polyester film composite paper, etc.

[0012] It should be emphasized that the staggered arrangement between the first protrusion and the second protrusion means that the first protrusion and the second protrusion exist both a circumferential gap and a radial gap, thereby improving the blocking effect on the insulating sheet.

[0013] Further, the insulating sheet can be directly connected to the stator winding by adhesive, and the specific position can be one side of the circumferential direction of the stator winding, and the insulating sheet can also be adhered on both sides of the circumferential direction.

[0014] The stator winding can be an enameled wire.

[0015] In the technical solution, in the circumferential direction of the stator core, the maximum dimension between the stator winding and the radial center line of the stator tooth is less than the maximum dimension between the first protrusion and the radial center line of the stator tooth; and / or the maximum dimension between the stator winding and the radial center line of the stator tooth is less than the maximum dimension between the second protrusion and the radial center line of the stator tooth.

[0016] In the technical solution, by limiting the maximum width of the stator winding and the maximum width of the first protrusion and the second protrusion, that is, for the first protrusion, at the outermost boundary of the stator winding, the maximum dimension in the circumferential direction is less than the maximum dimension of the first protrusion, and the maximum circumferential dimension of the stator winding is less than the maximum circumferential dimension of the first protrusion, so that when the insulating sheet is placed between the two adjacent stator windings, the movement range of the insulating paper is reduced, and the first protrusion can hinder the radial movement of the insulating paper. Similarly, for the second protrusion, by limiting the maximum circumferential dimension of the second protrusion to be greater than the maximum circumferential dimension of the stator winding, the movement range of the insulating paper is also limited, and the possibility of slipping is reduced.

[0017] Of course, the circumferential protruding length of the first protrusion and the second protrusion can be limited at the same time, or only the circumferential protruding length of one of the protrusions can be limited.

[0018] The radial center line of the stator tooth is the symmetry line of the stator tooth itself, and generally is the radial symmetry line passing through the axis of the stator core.

[0019] In the technical solution, the circumferential gap between the adjacent first protrusions and the second protrusions of the two adjacent first baffles is eccentric with respect to the radial center line of the winding slot, and the radial center line of the winding slot is the symmetry line between the two stator teeth, so that the direct leakage of the insulating paper from the circumferential gap between the adjacent first protrusions and the second protrusions is effectively reduced.

[0020] In the technical solution, by limiting the circumferential gap between the first protrusion and the second protrusion of the two adjacent first baffles, the circumferential gap between the first protrusion and the second protrusion is eccentric with respect to the radial center line of the winding slot, and the radial center line of the winding slot is the symmetry line between the two stator teeth, so that the direct leakage of the insulating paper from the circumferential gap between the adjacent first protrusions and the second protrusions is effectively reduced.

[0021] In the technical solution, the circumferential gap of the first protrusion and the second protrusion is less than the thickness of the insulating sheet.

[0022] In the technical solution, the circumferential gap between the first protrusion and the second protrusion is limited, that is, when the plurality of stator teeth are arranged, the first protrusion of one of the two adjacent stator teeth and the second protrusion of the other are close to each other, and the gap therebetween is smaller than the thickness of the insulating sheet, so that the insulating sheet cannot slip outwards through the gap between the first protrusion and the second protrusion, and the position of the insulating sheet is effectively limited.

[0023] In the above technical solution, the insulating frame body further comprises: a second baffle, which is arranged in the radial direction of the stator core and spaced apart from the first baffle, and the second baffle is arranged on the radial outer side of the first baffle, and the first baffle and the second baffle form a space for accommodating the insulating sheet with the adjacent two stator windings.

[0024] In the technical solution, the insulating frame body mainly comprises a first baffle and a second baffle, wherein the second baffle and the first baffle are spaced apart, and can jointly limit the position of the stator winding under the action of the first baffle and the second baffle. In addition, the first baffle and the second baffle can also be used to limit the position of the insulating sheet. Specifically, the first baffle and the second baffle are used to limit the radial movement range of the insulating sheet, and the insulating sheet is prevented from moving outward in the radial direction under the action of the second baffle. At this time, a space for accommodating the insulating sheet is formed under the action of the two adjacent stator windings, and the slipping direction only exists on the inner side of the radial direction. In addition, the first protrusion and the second protrusion are arranged, so that the anti-slip effect is improved.

[0025] The first baffle and the second baffle are connected by a connecting portion, and the shape of the connecting portion is matched with the shape of the stator tooth.

[0026] It can be understood that the shape of the connecting portion is matched with the shape of the stator tooth, and the shape of the connecting portion can be adjusted according to the shape of the stator tooth, so that the connecting portion can better fit the outer contour of the stator tooth, reduce unnecessary space waste, and ensure the winding space of the stator winding.

[0027] Further, the first baffle, the second baffle and the connecting portion are an integral structure.

[0028] Alternatively, the first baffle, the second baffle and the connecting portion are connected together in a split structure.

[0029] In the above technical solution, the stator core further comprises: a stator yoke, and a plurality of stator teeth are arranged on the stator yoke.

[0030] In the technical solution, the stator core further comprises a stator yoke, and a plurality of stator teeth are arranged on the stator yoke. After winding the stator teeth, the stator winding is formed. When the stator winding is energized, a magnetic field is formed, which facilitates the rotation of the rotor and provides magnetic force, thereby realizing rotation.

[0031] Generally, the stator yoke is annular, and the stator teeth are formed by extending radially inward from the inner side of the stator yoke.

[0032] In the above technical solution, the stator yoke is a one-piece structure; or the stator yoke is a split structure, and the stator yoke includes a plurality of yoke structures, and each stator tooth is connected to a corresponding yoke structure.

[0033] In this technical solution, the stator yoke itself is a one-piece structure, at this time the stator yoke as a whole is annular, by setting the stator teeth radially inward on the annular stator yoke, the stator yoke can play a certain limiting role radially outward for the winding operation on the stator teeth, and using a one-piece stator yoke can improve the overall strength of the stator assembly.

[0034] Further, the stator yoke is limited to a split structure, and the stator yoke is composed of a plurality of yoke structures, at this time each stator tooth is connected to a corresponding yoke structure, specifically, one yoke structure can be connected to one stator tooth, or one yoke structure can be connected to a plurality of stator teeth, as long as it can ensure the structural integrity in the circumferential direction after the plurality of yoke structures are spliced.

[0035] Further, it further includes a matching protrusion and a matching groove, and the matching protrusion and the matching groove are respectively arranged at the circumferential two ends of the yoke structure, and the connection of the plurality of yoke structures is realized through the cooperation of the matching protrusion and the matching groove.

[0036] In this technical solution, by setting the matching protrusion and the matching groove at the two ends of the yoke structure, the connection of the two adjacent yoke structures can be realized under the action of the matching protrusion and the matching groove, and under the action of the matching protrusion and the matching groove, the two yoke structures have a connection relationship, thereby realizing the structural integrity of the stator yoke as a whole.

[0037] In the above technical solution, the insulating sheet includes a planar sheet and / or a curved sheet.

[0038] In this technical solution, the cross section of the insulating sheet can be linear or curved, that is, the insulating sheet itself is planar or curved, and it can also be directly combined by a plurality of planar sheets to form a broken line sheet, or combined by a planar sheet and a curved sheet to form a specific structure.

[0039] In the above technical solution, the radial position of the first protrusion and the radial position of the second protrusion are completely non-overlapping.

[0040] In the technical solution, the radial positions of the first protrusion and the second protrusion are further limited, and the first protrusion and the second protrusion are completely not overlapped, that is, the radius range where the first protrusion is located and the radius range where the second protrusion is located are completely not overlapped in the radial direction of the stator core, so that after the plurality of stator windings are wound on the stator teeth, the insulating sheets placed between the stator windings are blocked by the first protrusion and the second protrusion, thereby achieving the effect of preventing sliding.

[0041] Embodiments of the second aspect of the present application provide a motor structure, comprising: a rotor structure; any one of the stator assemblies in the first aspect, coaxially arranged with the rotor structure, and the stator assembly is arranged on the outer side of the rotor structure.

[0042] The motor structure provided by the present application comprises a rotor structure and a stator assembly arranged coaxially, wherein the rotor structure is arranged on the inner side of the stator assembly, forming an inner rotor and an outer stator motor structure, and at this time a changing magnetic field is formed under the action of the stator assembly on the outer side, thereby driving the rotor structure to rotate.

[0043] In addition, since the motor structure comprises any one of the embodiments of the stator assembly, the motor structure has the beneficial effects of any one of the stator assemblies in the first aspect, which will not be repeated here.

[0044] Embodiments of the third aspect of the present application provide an electric power assisted steering system, comprising the motor structure of the embodiments of the second aspect, so that the electric power assisted steering system provided by the present application has all the beneficial effects of the motor structure provided in any one of the technical solutions.

[0045] The electric power assisted steering system is a direct electric power assisted steering system that relies on a motor to provide auxiliary torque power, and compared with a traditional hydraulic power assisted steering system (i.e., HPS system), the EPS system (i.e., electric power assisted steering system) has many advantages.

[0046] Further, the EPS mainly comprises a torque sensor, a vehicle speed sensor, a motor, a speed reduction mechanism, and an electronic control unit.

[0047] Embodiments of the fourth aspect of the present application provide a vehicle, comprising: a vehicle body; any one of the motor structures in the second aspect, arranged in the housing, or comprising the electric power assisted steering system in the third aspect.

[0048] The vehicle provided by the present application comprises a vehicle body and a motor structure arranged in the vehicle body, and the housing mainly protects the motor structure. Since the motor structure is arranged in the vehicle body, the vehicle has the beneficial effects of any one of the motor structures in the second aspect or the electric power assisted steering system in the third aspect, which will not be repeated here.

[0049] The motor structure in the vehicle can be used as a main driving structure, i.e. for an electric vehicle, and also as a driving structure for other devices in the vehicle, such as a fan, an electric power steering system, etc.

[0050] Additional aspects and advantages of the present application will become apparent from the following description with reference to the drawings. BRIEF DESCRIPTION OF DRAWINGS

[0051] Figure 1 A structural schematic diagram of a stator assembly according to an embodiment of the present application is shown;

[0052] Figure 2 A structural schematic diagram of a stator assembly according to an embodiment of the present application is shown;

[0053] Figure 3 A partial structural schematic diagram of a stator assembly according to an embodiment of the present application is shown;

[0054] Figure 4 A partial structural schematic diagram of a stator assembly according to an embodiment of the present application is shown;

[0055] Figure 5 A partial structural schematic diagram of a stator assembly according to an embodiment of the present application is shown;

[0056] Figure 6 A structural schematic diagram of a mating protrusion and mating groove according to an embodiment of the present application is shown;

[0057] Figure 7 A structural schematic diagram of a motor structure according to an embodiment of the present application is shown;

[0058] Figure 8 A structural schematic diagram of an electric power steering system according to an embodiment of the present application is shown;

[0059] Figure 9 A structural schematic diagram of a vehicle according to an embodiment of the present application is shown;

[0060] Figure 10 A structural schematic diagram of a vehicle according to an embodiment of the present application is shown.

[0061] wherein, Figures 1 to 10 The correspondence between the reference signs and the component names in the accompanying drawings is as follows:

[0062] 100: stator assembly; 102: stator core; 1022: stator yoke; 1023: yoke structure; 1024: stator tooth; 104: insulation frame; 1042: first baffle; 1044: second baffle; 1048: first protrusion; 1050: second protrusion; 106: stator winding; 108: insulation sheet; 1102: matching protrusion; 1104: matching groove; 200: motor structure; 202: rotor structure; 300: vehicle; 302: vehicle body; 400: electric power assisted steering system; 411: steering wheel; 412: steering shaft; 413: universal joint; 414: rotating shaft; 415: rack and pinion mechanism; 416: rack shaft; 417: wheel; 421: steering torque sensor; 422: control unit; 423: deceleration mechanism. DETAILED DESCRIPTION

[0063] In order to enable a more clear understanding of the above-mentioned purposes, features and advantages of the embodiments of the present application, the embodiments of the present application are further described in detail below in conjunction with the accompanying drawings and specific embodiments. It should be noted that the embodiments of the present application and the features in the embodiments can be combined with each other without conflict.

[0064] In the following description, a large number of specific details are set forth in order to facilitate a thorough understanding of the present application, however, the embodiments of the present application can also be implemented in other ways different from those described herein, and therefore, the protection scope of the present application is not limited to the specific embodiments disclosed below.

[0065] The following refers to Figures 1 to 10 described according to some embodiments of the present application.

[0066] Embodiment One

[0067] As shown in Figure 1 and Figure 2 The stator assembly 100 proposed in the embodiment includes a stator core 102, an insulation frame 104, an insulation sheet 108 and a stator winding 106, wherein the stator core 102 as the main electromagnetic structure includes a plurality of stator teeth 1024, which can provide winding support for the stator winding 106, facilitate subsequent generation of magnetic field, and further drive the rotor structure to rotate. Specifically, in order to reduce the direct contact between the stator winding 106 and the stator core 102, and reduce the possibility of short-circuiting and burning the motor due to accidental damage to the stator winding 106, the insulation frame 104 is further arranged between the stator tooth 1024 and the stator winding 106, which can effectively isolate the electrical contact between the stator tooth 1024 and the stator winding 106. Even if the outer skin of the stator winding 106 is damaged, it still cannot directly contact the stator tooth 1024, thereby ensuring the safety of the stator assembly 100 during installation and the overall use safety of the motor structure.

[0068] In the scheme, an insulating sheet 108 is arranged between the two adjacent stator windings 106. Under the action of the insulating sheet 108, the stator winding 106 can be effectively electrically insulated, thereby ensuring the safety of the motor during use. It should be understood that the insulating sheet 108 needs to insulate the stator winding 106, and the position thereof is between the two adjacent stator windings 106. For the stator winding 106, due to the difference in the radius, the size of the radial outside and the size of the radial inside of the stator winding 106 will also be different, and generally, the outside is larger and the inside is smaller. At this time, in order to prevent the insulating sheet 108 from being stable during the operation of the motor, ensure that the position thereof is stable between the windings, reduce the possibility of slipping inward into the air gap between the stator and the rotor, and achieve the effect of stabilizing the insulation, staggered protrusions, i.e., the first protrusion 1048 and the second protrusion 1050, are arranged at the radial inside of the insulating frame 104, i.e., at both ends of the first baffle 1042. After the plurality of stator windings 106 are wound on the stator teeth 1024, the insulating sheet 108 placed between the stator windings 106 will be blocked by the first protrusion 1048 and the second protrusion 1050, thereby achieving the effect of preventing slipping.

[0069] The first protrusion and the second protrusion are at least partially non-overlapping in the radial direction.

[0070] Further, the first protrusion and the second protrusion are completely non-overlapping in the radial direction.

[0071] The insulating sheet 108 can be connected to one circumferential side of the stator winding 106 by means of adhesion. Alternatively, the insulating sheet 108 can be connected to both circumferential sides of the stator winding 106.

[0072] It should be emphasized that the staggered arrangement between the first protrusion 1048 and the second protrusion 1050 means that the first protrusion 1048 and the second protrusion 1050 have both circumferential gaps and radial gaps, thereby improving the blocking effect of the insulating sheet 108.

[0073] Further, the insulating sheet 108 can be directly connected to the stator winding 106 by means of adhesion, and the specific position can be one circumferential side of the stator winding 106, or the insulating sheet 108 can be adhered on both circumferential sides.

[0074] The stator winding 106 can be an enameled wire.

[0075] Further, the thickness of the insulation sheet 108 needs to be greater than the circumferential gap between the first protrusion 1048 and the second protrusion 1050. When the plurality of stator teeth 1024 are arranged, the first protrusion 1048 of one of the two adjacent stator teeth 1024 and the second protrusion 1050 of the other are close to each other, and the gap between them is smaller than the thickness of the insulation sheet 108, so as to ensure that the insulation sheet 108 cannot slip outwards through the gap between the first protrusion 1048 and the second protrusion 1050, and better limit the position of the insulation sheet 108.

[0076] Further, the circumferential gap between the first protrusion 1048 and the second protrusion 1050 of the two adjacent first baffles 1042 is limited, and the circumferential gap between the first protrusion 1048 and the second protrusion 1050 is eccentric. The radial center line between the two stator teeth 1024 is the center line of the stator slot, that is, the radial center line of the circumferential gap is eccentric to the center line of the stator slot, which can effectively reduce the direct leakage of the insulation paper from the circumferential gap between the two adjacent first protrusions 1048 and second protrusions 1050.

[0077] For the insulation sheet 108, the cross section of the insulation sheet 108 can be linear or curved, that is, the insulation sheet 108 itself is a plane or a curved surface, and can also be directly combined by a plurality of plane sheets to form a broken line sheet, or combined by a plane sheet and a curved surface sheet to form a specific structure.

[0078] In a specific embodiment, as shown in Figures 1 to 4 A stator structure is provided, including a stator core 102, an insulation frame, an enameled wire (i.e., a stator winding 106), and an insulation paper (i.e., an insulation sheet 108). The insulation frame includes a first blocking part (i.e., a first protrusion) and a second blocking part (i.e., a second protrusion), and the circumferential gap L3 between the first blocking part and the second blocking part is less than the thickness of the insulation paper. The first blocking part and the second blocking part are radially staggered to reduce the circumferential movement space of the insulation paper. When the circumferential gap L3 between the first blocking part and the second blocking part is constant, the farther the second blocking part is from the center position (i.e., staggered radially arranged with the first blocking part), the less likely the insulation paper is to fall off from L3. The insulation paper is bonded by a bonding process. The circumferential protrusion length L4 of the second blocking part is greater than the circumferential distance L5 of the enameled wire edge.

[0079] The stator core 102 is a block structure and is composed of an even number of spliced parts to form a complete stator core 102. The enameled wire is mainly for motor current. The insulation frame mainly serves as insulation between the stator core 102 and the enameled wire. The insulation paper mainly serves as interphase insulation.

[0080] According to the above specific embodiments, the problem of motor failure caused by the insulation paper of the motor phase, especially the EPS motor, falling off due to vibration and other reasons into the air gap between the motor stator and the rotor can be effectively solved.

[0081] In addition, as shown in Figure 3 、 Figure 4 and Figure 5 , L1 is the shortest gap of the phase winding, that is, the shortest gap between the two adjacent stator windings, L2 is the circumferential protruding length of the second protrusion 1050, L3 is the circumferential gap between the first protrusion 1048 and the second protrusion 1050, L4 is the circumferential protruding length of the first protrusion 1048, and L5 is the circumferential distance of the edge of the enameled wire.

[0082] Embodiment two

[0083] As shown in Figure 1 , the stator assembly 100 proposed in this embodiment includes a stator core 102, an insulation frame 104, an insulation sheet 108, and a stator winding 106. The stator core 102 serves as the main electromagnetic structure and includes a plurality of stator teeth 1024, which provide winding support for the stator winding 106, facilitate the generation of a magnetic field, and thus drive the rotation of the rotor structure. Specifically, to reduce direct contact between the stator winding 106 and the stator core 102 and to reduce the possibility of short-circuiting and burning the motor due to accidental damage to the stator winding 106, an insulation frame 104 is provided between the stator teeth 1024 and the stator winding 106. Under the action of the insulation frame 104, the electrical contact between the stator teeth 1024 and the stator winding 106 can be effectively isolated. Even if the outer skin of the stator winding 106 is damaged, it still cannot directly contact the stator teeth 1024, thereby ensuring the safety of the stator assembly 100 during installation and the overall safety of the motor structure.

[0084] wherein the first protrusion and the second protrusion at least partially do not overlap in the radial direction.

[0085] Further, the first protrusion and the second protrusion completely do not overlap in the radial direction.

[0086] It is emphasized that in the present embodiment, by limiting the maximum width of the stator winding 106 and the maximum width of the first protrusion 1048 and the second protrusion 1050, i.e. for the first protrusion 1048, the maximum dimension in the circumferential direction at the outermost boundary of the stator winding 106 will be smaller than the maximum dimension of the first protrusion 1048, and the maximum circumferential dimension of the stator winding 106 will be smaller than the maximum circumferential dimension of the first protrusion 1048, taking the radial centerline of the stator tooth 1024 as the reference line, so as to reduce the movement range of the insulation paper when the insulation paper 108 is placed between two adjacent stator windings 106, and at the same time the first protrusion can hinder the radial movement of the insulation paper. Similarly, for the second protrusion 1050, by limiting the maximum circumferential dimension of the second protrusion 1050 to be greater than the maximum circumferential dimension of the stator winding 106, it is also beneficial to limit the movement range of the insulation paper and reduce the possibility of slipping.

[0087] Of course, the circumferential protruding length of the first protrusion 1048 and the second protrusion 1050 can be limited at the same time, or only the circumferential protruding length of one of the protrusions can be limited.

[0088] Here, the radial centerline of the stator tooth 1024 is the symmetry line of the stator tooth 1024 itself, and generally it is the radial symmetry line passing through the axis of the stator core 102.

[0089] In a specific embodiment, only the circumferential dimension of the first protrusion 1048 is limited, and in the circumferential direction of the stator core 102, the maximum dimension between the stator winding 106 and the radial centerline of the stator tooth 1024 is smaller than the maximum dimension between the first protrusion 1048 and the radial centerline of the stator tooth 1024.

[0090] In another specific embodiment, only the circumferential dimension of the second protrusion 1050 is limited, and in the circumferential direction of the stator core 102, the maximum dimension between the stator winding 106 and the radial centerline of the stator tooth 1024 is smaller than the maximum dimension between the second protrusion 1050 and the radial centerline of the stator tooth 1024.

[0091] In the scheme, the insulating sheet 108 is further arranged between the two adjacent stator windings 106, and under the action of the insulating sheet 108, the stator winding 106 can be effectively electrically insulated to ensure the safety of the motor in use. It can be understood that the insulating sheet 108 needs to isolate the stator winding 106, and the position is between the two adjacent stator windings 106. For the stator winding 106, due to the difference in the radius, the size of the radial outside and the size of the radial inside of the stator winding 106 will also be different, generally large outside and small inside. At this time, in order to prevent the stability of the insulating sheet 108 during the operation of the motor, ensure that its position can be stable between the windings, reduce the possibility of slipping inward to the air gap between the stator and the rotor, and achieve the effect of stabilizing the insulation, staggered protrusions, i.e. the first protrusion 1048 and the second protrusion 1050, will be arranged at the radial inside of the insulating frame 104, i.e. the two ends of the first baffle 1042. After the plurality of stator windings 106 are wound on the stator teeth 1024, the insulating sheet 108 placed between the stator windings 106 will be blocked by the first protrusion 1048 and the second protrusion 1050, thereby achieving the effect of preventing sliding.

[0092] It needs to be emphasized that the staggered arrangement between the first protrusion 1048 and the second protrusion 1050 is that the first protrusion 1048 and the second protrusion 1050 exist both circumferential gap and radial gap, which improves the blocking effect of the insulating sheet 108.

[0093] Further, the insulating sheet 108 can be directly connected to the stator winding 106 by adhesive, and the specific position can be the circumferential side of the stator winding 106, and the insulating sheet 108 can also be adhered on both circumferential sides.

[0094] Among them, the stator winding 106 can be an enameled wire.

[0095] Example three

[0096] As Figure 1 and Figure 2As shown, the stator assembly 100 proposed in this embodiment includes a stator core 102, an insulation frame 104, an insulation sheet 108 and a stator winding 106. The stator core 102, as the main electromagnetic structure, includes a plurality of stator teeth 1024, which can provide winding support for the stator winding 106, facilitate the generation of a magnetic field, and thus drive the rotation of the rotor structure. Specifically, in order to reduce direct contact between the stator winding 106 and the stator core 102 and reduce the possibility of short-circuiting and burning the motor due to accidental damage to the stator winding 106, an insulation frame 104 is arranged between the stator teeth 1024 and the stator winding 106. Under the action of the insulation frame 104, the electrical contact between the stator teeth 1024 and the stator winding 106 can be effectively insulated. Even if the outer skin of the stator winding 106 is damaged, it still cannot directly contact the stator teeth 1024, thereby ensuring the safety of the stator assembly 100 during installation and the overall safety of the motor structure.

[0097] In this scheme, an insulation sheet 108 is arranged between the two adjacent stator windings 106. Under the action of the insulation sheet 108, the stator winding 106 can be effectively electrically insulated to ensure the safety of the motor during use. It can be understood that the insulation sheet 108 needs to insulate the stator winding 106, and its position is between the two adjacent stator windings 106. Due to the different radii, the size of the radially outer side and the radially inner side of the stator winding 106 will also be different, generally larger on the outside and smaller on the inside. At this time, in order to prevent the insulation sheet 108 from being stable during the operation of the motor, ensure that its position can be stable between the windings, reduce the possibility of slipping inward into the air gap between the stator and the rotor, and achieve the effect of stabilizing the insulation, staggered protrusions, i.e., first protrusions 1048 and second protrusions 1050, are arranged on the radially inner side of the insulation frame 104, i.e., the two ends of the first baffle 1042. After the winding of the plurality of stator windings 106 on the stator teeth 1024 is completed, the insulation sheet 108 placed between the stator windings 106 will be blocked by the first protrusions 1048 and the second protrusions 1050, thereby achieving the effect of preventing slipping.

[0098] Further, the first protrusions and the second protrusions do not overlap in the radial direction.

[0099] Further, the first protrusions and the second protrusions do not overlap in the radial direction.

[0100] Wherein, for the insulating frame 104, mainly comprising a first baffle 1042, a second baffle 1044 and a connecting portion, the second baffle 1044 is arranged at intervals with the first baffle 1042, the shape of the connecting portion is matched with the shape of the stator tooth 1024, by arranging the first baffle 1042 and the second baffle 1044 on the opposite sides of the connecting portion, the stator winding 106 can be blocked by the joint action of the first baffle 1042 and the second baffle 1044, and the position of the stator winding 106 is limited.

[0101] It can be understood that the shape of the connecting portion is matched with the shape of the stator tooth 1024, the shape of the connecting portion can be adjusted according to the shape of the stator tooth 1024, so that the outer contour of the connecting portion can be better fitted with the stator tooth 1024, unnecessary space waste is reduced, and the winding space of the stator winding 106 is ensured.

[0102] In a specific embodiment, the first baffle 1042, the second baffle 1044 and the connecting portion are an integral structure.

[0103] In another specific embodiment, the first baffle 1042, the second baffle 1044 and the connecting portion are connected together in a split structure.

[0104] Further, the stator core 102 further comprises a stator yoke 1022, by arranging a plurality of stator teeth 1024 on the stator yoke 1022, the stator winding 106 can be formed after winding on the stator tooth 1024, at this time, when the stator winding 106 is energized, a magnetic field is formed, thereby facilitating the rotation of the rotor to provide magnetic force, so as to realize rotation.

[0105] Generally, the stator yoke 1022 is annular, and the stator tooth 1024 is formed by extending radially from the inner side of the stator yoke 1022.

[0106] For the stator yoke 1022, it can be an integral structure, at this time, the stator yoke 1022 is annular as a whole, by arranging the stator tooth 1024 radially on the inner side of the annular stator yoke 1022, the stator yoke 1022 can limit the winding operation of the stator tooth 1024 radially on the outer side, and the integral stator yoke 1022 can improve the overall strength of the stator assembly 100.

[0107] Or a split structure, the stator yoke 1022 is composed of a plurality of yoke structures 1023, at this time, each stator tooth 1024 is connected with the yoke structure 1023, specifically, one yoke structure 1023 can be connected with one stator tooth 1024, or one yoke structure 1023 can be connected with a plurality of stator teeth 1024, as long as it can ensure the structural integrity in the circumferential direction after splicing the plurality of yoke structures 1023.

[0108] For the split stator yoke 1022, as shown in Figure 6 The matching protrusion 1102 and the matching groove 1104 are arranged at both ends of the yoke structure 1023, so that the connection of the two adjacent yoke structures 1023 can be realized under the action of the matching protrusion 1102 and the matching groove 1104. Under the action of the matching protrusion 1102 and the matching groove 1104, the two yoke structures 1023 are connected, so as to realize the structural integrity of the whole stator yoke 1022.

[0109] It should be emphasized that the staggered arrangement between the first protrusion 1048 and the second protrusion 1050 means that there are both circumferential gaps and radial gaps between the first protrusion 1048 and the second protrusion 1050, which improves the blocking effect on the insulating sheet 108.

[0110] Further, the insulating sheet 108 can be directly connected to the stator winding 106 by adhesive, and the specific position can be the circumferential side of the stator winding 106. There can also be insulating sheets 108 on both circumferential sides.

[0111] Among them, the stator winding 106 can be an enameled wire.

[0112] Embodiment Four

[0113] As shown in Figure 7 The motor structure 200 provided in the embodiment includes a rotor structure 202 and a stator assembly 100 arranged coaxially, wherein the rotor structure 202 is arranged on the inner side of the stator assembly 100, forming an outer stator inner rotor motor structure 200. At this time, under the action of the stator assembly 100 on the inner side, a changing magnetic field will be formed, thereby driving the rotor structure 202 to rotate.

[0114] In addition, since the motor structure 200 includes any of the above embodiments of the stator assembly 100, it has the beneficial effects of any of the stator assemblies 100 in the first aspect, which will not be repeated here.

[0115] Embodiment Five

[0116] As shown in Figure 8 The electric power assisted steering system 400 provided in the embodiment includes the motor structure 200 as in any of the above possible embodiments, so the electric power assisted steering system 400 provided in the embodiment has all the beneficial effects of the motor structure 200 provided in the above embodiments.

[0117] Among them, the electric power steering system 400 (Electric Power Steering, EPS for short) is a kind of electric power steering system which directly relies on the motor structure 200 to provide auxiliary torque power. Compared with the traditional hydraulic power steering system HPS (Hydraulic Power Steering), the EPS system has simple structure and flexible assembly, can save energy and protect the environment, and most of the models of modern vehicles are basically equipped with EPS system.

[0118] The electric power steering system 400 includes various implementable modes. Among them, one of the various implementable modes will be described in detail below. Specifically, in one implementable mode, the EPS system has an electric power steering system and an auxiliary torque mechanism that generates an auxiliary torque. The auxiliary torque assists the steering torque of the electric power steering system generated by the driver operating the steering wheel. Through the auxiliary torque, the burden of the driver's operation is reduced.

[0119] Among them, the electric power steering system 400 specifically includes a steering wheel 411, a steering shaft 412, a universal coupling 413, a rotating shaft 414, a rack and pinion mechanism 415, a rack shaft 416, and left and right steering wheels 417, etc.

[0120] Among them, the auxiliary torque mechanism specifically includes a steering torque sensor 421, an electronic control unit for automobiles 422, a motor, and a speed reduction mechanism 423, etc. Specifically, the steering torque sensor 421 detects the steering torque of the electric power steering system. The control unit 422 generates a driving signal according to the detection signal of the steering torque sensor 421. The motor generates an auxiliary torque corresponding to the steering torque according to the driving signal. The motor transmits the generated auxiliary torque to the electric power steering system through the speed reduction mechanism 423.

[0121] Embodiment six

[0122] As shown in Figure 9 The vehicle 300 proposed in the embodiment includes a vehicle body 302 and a motor structure 200 arranged in the vehicle body 302. The vehicle body 302 mainly plays a certain protective role for the motor structure 200. Since the vehicle body 302 is provided with the motor structure 200, it has the beneficial effects of any of the embodiments of the motor structure 200 or the electric power steering system 400 described above, which will not be repeated here.

[0123] Among them, the motor structure in the vehicle can be used as the main driving structure, that is, the electric vehicle, and also can be used as the driving structure of other equipment in the vehicle, such as a fan, etc.

[0124] Of course, the motor structure 200 can also be used to drive, for example Figure 10The electric power assisted steering system 400 is shown, thereby realizing steering of the vehicle 300.

[0125] According to the stator assembly, the motor structure, the electric power assisted steering system and the vehicle provided by the application, by limiting the radial outer side surface of the first baffle to be a plane, that is, the surface of the side of the first baffle facing the second baffle is a plane, the fastening degree of each turn can be ensured during winding, since each turn directly contacts the first baffle and the radial outer side surface of the first baffle is a plane, there is no left and right sliding force of the arc-shaped curved surface during winding, and the winding efficiency is greatly enhanced.

[0126] In the present application, the terms "first", "second", "third" are only used for the purpose of description, and should not be understood as indicating or implying relative importance; the term "multiple" refers to two or more, unless otherwise explicitly limited. The terms "mounting", "connecting", "connecting", "fixing" and the like should be broadly understood, for example, "connecting" can be fixed connection, or detachable connection, or integrally connected; "connected" can be directly connected, or indirectly connected through an intermediate medium. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0127] In the description of the present application, it should be understood that the terms "upper", "lower", "left", "right", "front", "back" and the like indicate the orientation or positional relationship shown in the drawings, and are only for the purpose of facilitating the description of the present application and simplifying the description, and do not indicate or imply that the devices or units referred to must have a particular direction, be constructed and operated in a particular orientation, therefore, it should not be understood as a limitation on the present application.

[0128] In the description of the present application, the terms "one embodiment", "some embodiments", "a specific embodiment" and the like mean that the specific features, structures, materials or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present application. In the present specification, the illustrative description of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.

[0129] The above is only the preferred embodiment of the present application, and is not intended to limit the present application. For those skilled in the art, the present application can have various modifications and changes. Any modification, equivalent replacement, improvement, etc. made within the spirit and principles of the present application shall be included in the protection scope of the present application.

Claims

1. A stator assembly characterized by, The stator core comprises a plurality of stator teeth, each of which is wound with a stator winding; An insulation frame is arranged at both ends of the stator teeth in the axial direction of the stator core, and the insulation frame comprises a first baffle arranged at the radially inner side of the stator core; An insulation sheet is arranged on at least one side of the stator winding of each stator tooth in the circumferential direction of the stator core; The circumferential ends of the first baffle are respectively provided with a first protrusion and a second protrusion, the radial position of the first protrusion and the radial position of at least part of the second protrusion do not overlap, the first protrusion of one of the two adjacent first baffles is arranged adjacent to the second protrusion of the other first baffle, and there is a circumferential gap between the adjacent first protrusion and the second protrusion; The first protrusion and the second protrusion have both the circumferential gap and a radial gap; The circumferential gap is asymmetric about the radial center line of the winding slot formed between the two adjacent stator teeth. In the circumferential direction of the stator core, the maximum dimension between the stator winding and the radial center line of the stator tooth is smaller than the maximum dimension between the first protrusion and the radial center line of the stator tooth; and / or 2. The stator assembly of claim 1, wherein, The maximum dimension between the stator winding and the radial center line of the stator tooth is smaller than the maximum dimension between the second protrusion and the radial center line of the stator tooth. The circumferential gap of the first protrusion and the second protrusion is smaller than the thickness of the insulation sheet.

3. The stator assembly of claim 1, wherein, The insulation frame further comprises:

4. The stator assembly of claim 1, wherein, A second baffle is arranged spaced apart from the first baffle in the radial direction of the stator core, the second baffle is arranged at the radially outer side of the first baffle, and the first baffle and the second baffle form a space for accommodating the insulation sheet with the two adjacent stator windings. The stator core further comprises:

5. The stator assembly of claim 1, wherein, A stator yoke on which a plurality of stator teeth are arranged. The stator yoke is a one-piece structure; or 6. The stator assembly of claim 5, wherein, The stator yoke is a split structure, and the stator yoke comprises a plurality of yoke structures, each stator tooth being connected to the corresponding yoke structure. The insulation sheet comprises a planar sheet and / or a curved sheet.

7. The stator assembly of claim 1, wherein, The radial position of the first protrusion and the radial position of the second protrusion do not overlap at all.

8. The stator assembly of claim 1, wherein, The rotor structure; 9. An electric machine structure, characterized by The stator assembly according to any one of claims 1 to 8 is coaxially arranged with the rotor structure. The motor structure according to claim 9 is included. The vehicle body; 10. An electric power assisted steering system characterised in that, The motor structure according to claim 9 is arranged in the vehicle body; or 11. A vehicle characterized by comprising: The electric power assisted steering system according to claim 10 is arranged in the vehicle body. ​ ​ ​ ​

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