A stator structure and method of assembly thereof

Abstract

The application discloses a stator structure and an assembling method thereof. The stator structure comprises a stator core, a plurality of stator teeth are arranged in the stator core in a circumferential direction, an armature assembly is sleeved on the stator teeth in the circumferential direction, a connecting assembly is arranged at an end of the stator core, and is used for connecting two adjacent armature assemblies in series to form a non-closed ring structure, one end of the ring structure is connected with a lead-out wire, and the other end is connected to a center line assembly. A plurality of copper bar structures are arranged in the connecting assembly, each copper bar structure comprises a first copper bar, a second copper bar and a third copper bar which are arranged in a laminated and spaced manner, each copper bar structure is integrally formed by injection molding of an insulating medium, and the first copper bar, the second copper bar and the third copper bar are connected in series with adjacent homopolar armature windings. In the above manner, the application can achieve the insulation effect by injection molding, and the series connection between the homopolar armature windings can be realized by using the copper bar, the bending and welding of the lead-out wire are reduced, and the working efficiency is effectively improved.

Description

Technical Field

[0001] This application relates to the field of motor technology, and specifically to a stator structure and its assembly method. Background Technology

[0002] The motor body generally consists of components such as the stator, rotor, and end covers. The stator includes the stator core, insulating frame, and windings. In existing technologies, such as... Figure 1 As shown, some stator ends are directly welded together using the tail leads of the armature windings, which requires multiple bends and connections of the leads, resulting in longer lead lengths, higher costs, and manual operation during the welding process, leading to low work efficiency. Other stator ends use a layered structure, using bridging wires to connect the armature windings to each other. However, the layers of bridging wires need to be separated by insulating pads, making the operation more complicated and resulting in lower work efficiency. Summary of the Invention

[0003] To overcome the above-mentioned shortcomings, the purpose of this application is to provide a stator structure and its assembly method that modularizes the end structure, reduces lead wire length, and improves working efficiency.

[0004] To achieve the above objectives, this application adopts the following technical solution:

[0005] A stator structure includes: a stator core, wherein a plurality of stator teeth are arranged circumferentially inside the core, and each group of stator teeth includes B teeth, A teeth and C teeth arranged sequentially;

[0006] An armature assembly is sleeved around the stator teeth, and the armature assembly is correspondingly provided with a B-phase armature winding, an A-phase armature winding, and a C-phase armature winding;

[0007] A connecting assembly, which is disposed at the end of the stator core, is used to connect two adjacent armature assemblies in series to form a non-closed ring structure. One end of the ring structure is connected to a lead wire, and the other end is connected to the center line assembly.

[0008] The connection assembly is internally provided with multiple sets of copper busbar structures. Each set of copper busbar structures includes a first copper busbar, a second copper busbar, and a third copper busbar arranged in a stacked and spaced manner. Each set of copper busbar structures is integrally formed by injection molding of insulating medium. The first copper busbar, the second copper busbar, and the third copper busbar are connected in series with adjacent armature windings of the same phase.

[0009] In a preferred embodiment, the centerline assembly is provided with a D-end connection, an E-end connection, and an F-end connection, which are respectively connected to armature windings of different phases.

[0010] In a preferred embodiment, the leads include a B-phase lead, an A-phase lead, and a C-phase lead, which are respectively connected to armature windings of different phases.

[0011] In a preferred embodiment, the connection assembly includes a plurality of first bridge wire assemblies, each set of first bridge wire assemblies being integrally formed from a set of copper busbar structures through injection molding of an insulating medium, and the first bridge wire assemblies being disposed on the end face of the stator core through a first positioning structure.

[0012] In a preferred embodiment, the first positioning structure includes a first positioning post disposed at the end of the stator core, and a first positioning hole is provided on one end face of the first bridge wire assembly near the stator core, and the first positioning post is inserted into the first positioning hole.

[0013] In a preferred embodiment, two adjacent first bridge line assemblies are connected and configured with second bridge line assemblies by a second positioning structure, and each set of second bridge line assemblies is integrally formed by a set of copper busbar structures through injection molding of insulating medium.

[0014] In a preferred embodiment, the second positioning structure includes a second positioning hole provided on the side of the first bridge wire assembly away from the stator core, and a second positioning post provided on the end face of the second bridge wire assembly near the first bridge wire assembly, the second positioning post being inserted into the second positioning hole.

[0015] In a preferred embodiment, two adjacent copper busbars are spaced apart by fasteners, and the fasteners are provided with at least two slots.

[0016] In a preferred embodiment, the distance between two adjacent slots is 1.4-1.6 mm.

[0017] An assembly method for a stator structure, comprising the following steps:

[0018] S1: The first copper busbar, the second copper busbar, and the third copper busbar are assembled and then integrally injection molded to generate a connecting component;

[0019] S2: Sequentially embed the armature assembly into the stator teeth of the stator core;

[0020] S3: Assemble the connecting components sequentially to the ends of the stator core;

[0021] S4: Weld the copper busbar to the lead-out end of the armature assembly;

[0022] S5: Connect the lead wire and center wire assembly to the lead-out terminals of the armature assembly that are not connected to the copper busbar.

[0023] Beneficial effects

[0024] The stator structure proposed in this application connects the armature winding and the lead wires through modular connection components. The connection components include a first bridge wire assembly and a second bridge wire assembly with specific modular configurations. Both have copper busbar structures inside, and the copper busbars replace the lead wires to connect the armature windings of the same phase in series, which effectively reduces the length of the lead wires and the bending steps of the lead wires, thus effectively improving working efficiency.

[0025] The copper busbar is integrally molded by injection molding, resulting in a relatively stable structure, high structural strength, and good seismic performance. The insulation effect is achieved through the injection-molded insulating medium, eliminating the need for manual placement of additional insulating blocks, saving manpower, and effectively improving work efficiency. Attached Figure Description

[0026] The accompanying drawings are provided to illustrate the technical solutions of this disclosure and form part of the specification. They are used together with the embodiments of this disclosure to explain the technical solutions of this disclosure and do not constitute a limitation on the technical solutions of this disclosure. The shapes and sizes of the components in the drawings do not reflect actual proportions and are only intended to illustrate the content of this application.

[0027] Figure 1 This is a three-dimensional schematic diagram of an existing stator structure in the background art of this application;

[0028] Figure 2 This is a three-dimensional structural diagram of the stator structure according to an embodiment of this application;

[0029] Figure 3 for Figure 2 A magnified view of a portion of point a;

[0030] Figure 4 This is an exploded structural diagram of the stator structure according to an embodiment of this application;

[0031] Figure 5 This is a schematic diagram of the A-phase armature winding of the stator structure in an embodiment of this application;

[0032] Figure 6 This is a three-dimensional structural diagram of the copper busbar structure in the embodiments of this application;

[0033] Figure 7 This is a three-dimensional structural diagram of the first positioning element in an embodiment of this application;

[0034] Figure 8 This is a flowchart illustrating an assembly method for a stator structure according to this application;

[0035] Figure label:

[0036] 1. Stator core; 11. B tooth; 12. A tooth; 13. C tooth; 14. First positioning post;

[0037] 21. Phase B armature winding; 22. Phase A armature winding; 23. Phase C armature winding;

[0038] 31. First bridge cable assembly; 311. First positioning hole; 32. Second bridge cable assembly; 33. Centerline assembly; 331. D-end connection part; 332. E-end connection part; 333. F-end connection part;

[0039] 41. First copper bar; 42. Second copper bar; 43. Third copper bar;

[0040] 51. First card; 52. Second card; 53. Card slot;

[0041] 61. Phase B lead-out; 62. Phase A lead-out; 63. Phase C lead-out. Detailed Implementation

[0042] The above-described solution will be further illustrated below with reference to specific embodiments. It should be understood that these embodiments are for illustrative purposes only and are not intended to limit the scope of this application. The implementation conditions used in the embodiments may be further adjusted according to the conditions of specific manufacturers, and the implementation conditions not specified are generally those in routine experiments.

[0043] The stator structure (hereinafter referred to as the stator structure) proposed in this application will now be described with reference to the accompanying drawings.

[0044] like Figure 2 The figure shown is a three-dimensional structural diagram of the stator structure of this application.

[0045] The stator structure of this application includes: a stator core 1, with a plurality of stator teeth spaced circumferentially inside, an armature assembly fitted on the stator teeth, and a lead-out end provided at the end of the armature assembly. A connecting component is disposed on one end face of the stator core 1 near the lead-out end, and the connecting component is connected to the lead-out end of the armature assembly. Two adjacent armature assemblies are connected in series through the connecting component to form a non-closed ring structure. One end of the ring structure is connected to a lead wire, and the other end is connected to a center line assembly. The lead wire, armature assembly, and center line assembly are interconnected through the connecting component.

[0046] like Figure 2-7 As shown, the stator teeth include B teeth 11, A teeth 12, and C teeth 13 arranged sequentially. The armature assembly is correspondingly equipped with a B-phase armature winding 21, an A-phase armature winding 22, and a C-phase armature winding 23. Specifically, the B-phase armature winding 21 is circumferentially fitted onto the B teeth 11; the A-phase armature winding 22 is circumferentially fitted onto the A teeth 12; and the C-phase armature winding 23 is circumferentially fitted onto the C teeth 13.

[0047] like Figure 2-7As shown, in this embodiment, six sets of stator teeth are arranged circumferentially inside the stator core 1, and six sets of corresponding armature assemblies are also provided. Each phase armature winding has two leads at its end.

[0048] like Figure 2-7 As shown, the connecting assembly contains multiple sets of copper busbar structures, which connect adjacent armature windings of the same phase in series. Each set of copper busbar structures includes a first copper busbar 41, a second copper busbar 42, and a third copper busbar 43 arranged sequentially. The three copper busbars in each set are stacked alternately from top to bottom using fasteners and integrally molded with an insulating medium. The insulating medium fills the gaps within the copper busbar structure, thus achieving insulation between adjacent copper busbars. Furthermore, the integral molding of the copper busbar structure effectively improves its structural strength and enhances its seismic resistance.

[0049] like Figure 2-7 As shown, adjacent copper busbars are stacked with gaps using fasteners, each fastener having at least two slots 53. Preferably, the fasteners include a first fastener 51 and a second fastener 52, depending on the number of slots. The first fastener 51 has two slots to fix and separate the positions of adjacent copper busbars, such as fixing the first copper busbar 41 to the second copper busbar 42, and / or fixing the second copper busbar 42 to the third copper busbar 43. The second fastener 52 has three slots to fix the positions of the three copper busbars, effectively enhancing the stability of the overall internal structure of the bridging cable assembly. The number of first fasteners 51 and second fasteners 52 can be increased as needed. Fasteners can be installed on both the inner and outer sides of the bridging cable assembly to improve stability and enhance structural strength. Preferably, slots (not shown) are provided at the inner and outer edges of the first copper busbar 41, the second copper busbar 42, and the third copper busbar 43 for installing the fasteners. In this embodiment, each group of bridge wire assemblies is provided with four first clips 51 and four second clips 52. Preferably, the distance between two adjacent clip slots is 1.4-1.6mm. In this embodiment, the distance between two adjacent copper busbars is controlled to be 1.5mm, so that the overall structure of the stator core 1 end is relatively neat and has good consistency.

[0050] like Figure 2-7As shown, each group of copper busbars is arranged in a stacked, spaced manner in the vertical direction, with adjacent copper busbars fixed and separated by fasteners; in the horizontal direction, they are staggered, allowing each copper busbar to connect different groups of in-phase armature windings in series. In this embodiment, the two ends of the first copper busbar 41 are respectively connected to the leads of the B-phase armature windings 21 of the two adjacent groups, realizing the series connection of the B-phase armature windings 21, that is, one lead of a B-phase armature winding 21 is connected to a first copper busbar 41, and the other lead is connected to the first copper busbar in another group of copper busbar structures; the two ends of the second copper busbar 42 are respectively connected to the leads of the A-phase armature windings 22 of the two adjacent groups, realizing the series connection of the A-phase armature windings 22; the two ends of the third copper busbar 43 are respectively connected to the leads of the C-phase armature windings 23 of the two adjacent groups, realizing the series connection of the C-phase armature windings 23. The leads between the copper busbars and the armature windings are connected by welding, reducing the bending steps of the components and effectively improving work efficiency.

[0051] like Figure 2-7 As shown, the connecting assembly includes multiple sets of first bridging wire assemblies 31, each set of first bridging wire assemblies 31 being integrally formed from a set of copper busbar structures using injection molding of an insulating medium. The first bridging wire assemblies 31 are disposed at the ends of the stator core 1, connecting two adjacent armature assemblies. The first bridging wire assemblies 31 and the ends of the stator core 1 are positioned and connected via a first positioning structure. A second bridging wire assembly 32 is provided between two adjacent first bridging wire assemblies 31. Each second bridging wire assembly 32 is integrally formed from a set of copper busbar structures using injection molding of an insulating medium. The second bridging wire assembly 32 and the first bridging wire assembly 31 are positioned and connected via a second positioning structure. Through the control of the first and second positioning structures, precise relative position control is ensured, effectively improving installation efficiency. Furthermore, after assembly, no manual shaping is required, saving manpower.

[0052] like Figure 2-7 As shown, the first positioning structure includes a first positioning post 14 disposed at the end of the stator core 1. A first positioning hole 311 is provided on one end face of the first bridge wire assembly 31 near the stator core 1. The first positioning post 14 is inserted into the first positioning hole 311 to realize the assembly connection between the first bridge wire assembly 31 and the stator core 1, thereby achieving precise control of positioning during the assembly process and improving its assembly efficiency.

[0053] like Figure 2-7 As shown, the second positioning structure includes a second positioning hole (not shown) disposed on the end face of the first bridge wire assembly 31 opposite to the stator core 1, and a second positioning post (not shown) is provided on the end face of the second bridge wire assembly 32 close to the first bridge wire assembly 31. The positioning connection between the first bridge wire assembly 31 and the second bridge wire assembly 32 is realized by inserting the second positioning post into the second positioning hole, thereby enabling precise control of the relative position.

[0054] like Figure 2-7 As shown, the first positioning structure and the second positioning structure are generated during the injection molding process of the copper busbar structure according to different molds, and their specific positioning structures include, but are not limited to, the above-mentioned methods.

[0055] like Figure 2-7 As shown, the armature assembly forms an open ring structure in series with the copper busbar structure. One end of the armature assembly is connected to a lead wire, which specifically includes a B-phase lead wire 61, an A-phase lead wire 62, and a C-phase lead wire 63; the other end is connected to a center wire assembly 33.

[0056] like Figure 2-7 As shown, phase B lead 61 is connected to a lead of phase B armature winding 21 that is not connected to the first copper busbar 41, phase A lead 62 is connected to a lead of phase A armature winding 22 that is not connected to the second copper busbar 42, and phase C lead 63 is connected to a lead of phase C armature winding 23 that is not connected to the third copper busbar 43.

[0057] In this embodiment, the three-phase leads are connected to the armature winding by welding.

[0058] like Figure 2-7 As shown, the centerline assembly 33 includes a D-end connection portion 331, an E-end connection portion 332, and an F-end connection portion 333, which are respectively connected to the lead-out ends of the armature assembly that are not connected to copper busbars. Preferably, the above-mentioned connection portions are connected to the lead-out ends by welding, which effectively improves working efficiency.

[0059] like Figure 8 As shown, an assembly method for the above-mentioned stator structure is performed according to the following steps:

[0060] S1: The first copper busbar, the second copper busbar, and the third copper busbar are assembled and then integrally injection molded to generate a connecting component;

[0061] S2: Sequentially embed the armature assembly into the stator teeth of the stator core;

[0062] S3: Assemble the connecting components sequentially to the ends of the stator core;

[0063] S4: Weld the copper busbar to the lead-out end of the armature assembly;

[0064] S5: Connect the lead wire and center wire assembly to the lead-out terminals of the armature assembly that are not connected to the copper busbar.

[0065] The installation process is simple and involves fewer steps, effectively improving the assembly speed. Furthermore, the modular structure of the first and second bridge line components ensures a neat and consistent overall structure, eliminating the need for multiple manual reshaping operations and effectively saving manpower.

[0066] The above embodiments are only for illustrating the technical concept and features of this application, and are intended to enable those skilled in the art to understand the content of this application and implement it accordingly. They should not be used to limit the scope of protection of this application. All equivalent changes or modifications made in accordance with the spirit and essence of this application should be included within the scope of protection of this application.

Claims

1. A stator structure, characterized in that, include: The stator core has a number of stator teeth arranged circumferentially inside, and each group of stator teeth includes teeth B, A and C arranged in sequence. An armature assembly is sleeved around the stator teeth, and the armature assembly is correspondingly provided with a B-phase armature winding, an A-phase armature winding, and a C-phase armature winding; A connecting assembly, which is disposed at the end of the stator core, is used to connect two adjacent armature assemblies in series to form a non-closed ring structure. One end of the ring structure is connected to a lead wire, and the other end is connected to the center line assembly. The connection component is provided with multiple sets of copper busbar structures. Each set of copper busbar structures includes a first copper busbar, a second copper busbar, and a third copper busbar arranged in a stacked and spaced manner. Each set of copper busbar structures is integrally formed by injection molding of insulating medium. The first copper busbar, the second copper busbar, and the third copper busbar are connected in series with adjacent armature windings of the same phase. The connection assembly includes a plurality of first bridge wire assemblies. Each set of first bridge wire assemblies is integrally formed from a set of copper busbar structures through injection molding of insulating medium. The first bridge wire assemblies are configured on the end face of the stator core through a first positioning structure. Two adjacent first bridge line assemblies are connected by a second positioning structure and a second bridge line assembly is configured. Each group of second bridge line assemblies is integrally formed by a set of copper busbar structures through injection molding of insulating medium. The second positioning structure includes a second positioning hole opened on the side of the first bridge wire assembly away from the stator core, and a second positioning post is provided on one end face of the second bridge wire assembly near the first bridge wire assembly, and the second positioning post is inserted into the second positioning hole.

2. The stator structure as described in claim 1, characterized in that, The centerline assembly is equipped with a D-end connection, an E-end connection, and an F-end connection, which are respectively connected to the armature windings of different phases.

3. The stator structure as described in claim 1, characterized in that, The leads include phase B leads, phase A leads, and phase C leads, which are respectively connected to armature windings of different phases.

4. The stator structure as described in claim 1, characterized in that, The first positioning structure includes a first positioning post disposed at the end of the stator core, and a first positioning hole is provided on one end face of the first bridge wire assembly near the stator core, and the first positioning post is inserted into the first positioning hole.

5. The stator structure as described in claim 1, characterized in that, Adjacent copper busbars are spaced apart by fasteners, and the fasteners have at least two slots.

6. The stator structure as described in claim 5, characterized in that, The distance between two adjacent slots is 1.4-1.6 mm.

7. A method for assembling a stator structure, characterized in that: The assembly method, when applied to any of the stator structures described in claims 1 to 5, is performed according to the following steps: S1: The first copper busbar, the second copper busbar, and the third copper busbar are assembled and then integrally injection molded to generate a connecting component; S2: Sequentially embed the armature assembly into the stator teeth of the stator core; S3: Assemble the connecting components sequentially to the ends of the stator core; S4: Weld the copper busbar to the lead-out terminal of the armature assembly; S5: Connect the lead wire and center wire assembly to the lead-out terminals of the armature assembly that are not connected to the copper busbar.

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