Stator core, plastic package stator assembly, manufacturing method of plastic package stator assembly, motor and air conditioner

Abstract

The invention provides a stator core, a plastic package stator assembly, a manufacturing method of the plastic package stator assembly, a motor and an air conditioner, the stator core comprises two semi-circular iron core section split bodies, and the two semi-circular iron core section split bodies are respectively provided with assembling surfaces which are attached to each other to form a whole circle. The assembling surfaces of the two semicircular iron core section split bodies are spliced through a transverse sliding limiting structure, the transverse sliding limiting structure is located in the middle area of the axial length of each semicircular iron core section split body, and the sliding insertion direction of the transverse sliding limiting structure is the first diameter direction of the stator iron core. According to the stator assembly, more reliable limiting in the axial direction and the radial direction can be achieved after the two semicircular iron core sections are spliced in a split mode, then radial dislocation and deviation of the stator iron core due to impact of injection molding materials in the subsequent plastic packaging process can be prevented, the concentricity of the stator assembly is improved, and operation noise of a motor can be lowered.

Description

Technical Field

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

[0002] The PG motor used in household air conditioners is an AC plastic-encapsulated motor that uses thyristor speed control. It mainly consists of a stator assembly, a rotor assembly, a Hall assembly, and an end cover. The stator assembly is made of a stator core, a skeleton, and enameled wires by injection molding.

[0003] In the existing semicircular stator splicing structure, two groups of semicircular stator cores arranged opposite to each other are spliced ​​and connected to each other through a dovetail structure by plugging and buckling along the axial direction to realize the splicing connection between the two split core segments. Due to the lack of a limiting structure for the axial direction of the core, the split core segments are easily misaligned up and down. At the same time, in order to facilitate the axial splicing, the matching gap between the slots and buckles of the dovetail structure is often large (each punching sheet of the core stack needs to be punched first, and the slots and buckles are realized synchronously during the punching process, so that the core segments are not easily misaligned). The punching sheets of the type are stacked up and down, and the assembly shape and position deviations of the slots and buckles on different punching sheets are large. In order to ensure the smooth axial clamping assembly, a large deviation size needs to be reserved when stamping each punching sheet), that is, the design is relatively loose, which makes the up and down and left and right displacement of the stator core after splicing more obvious. When the stator is injection molded (also known as plastic sealing), the impact of the injection plastic will cause radial dislocation and offset of the core, resulting in poor stator concentricity, which in turn causes the corresponding motor to have more prominent noise problems during application. Summary of the invention

[0004] Therefore, the present invention provides a stator core, a plastic-sealed stator assembly and a manufacturing method thereof, a motor and an air conditioner, which can solve the technical problem in the prior art that the relative position of the stator core formed by splicing split core segments lacks necessary limitations, the vertical and horizontal displacement lines of the assembled stator core are relatively obvious, and radial dislocation and offset are very likely to occur under the impact of the injection molding material during the plastic sealing process of the stator core, thereby reducing the concentricity of the stator and causing noise.

[0005] In order to solve the above problems, the present invention provides a stator core, including two semicircular core segment splits, the assembly surfaces of the two semicircular core segment splits respectively fit together to form a whole circle, and the assembly surfaces of the two semicircular core segment splits respectively are spliced ​​by a transverse sliding limit structure, the transverse sliding limit structure is located in the middle area of ​​the axial length of each semicircular core segment split, and the sliding and plug-in direction of the transverse sliding limit structure is the first diameter direction of the stator core.

[0006] In some embodiments, the lateral sliding limit structure includes a hook formed on the first side circumferential wall of the semicircular core segment split and a groove formed on the second side circumferential wall of the semicircular core segment split, and the hook protrudes from the assembly surface of the semicircular core segment split, the first side and the second side are symmetrical about the central axis of the stator core, and when the two semicircular core segment splits are spliced ​​into the full circle, the hook body of the hook of one semicircular core segment split is embedded in the groove of the other semicircular core segment split.

[0007] In some embodiments, the hook also has a connector connected between the first side circumferential wall and the hook body, the connector protrudes radially outward from the first side circumferential wall, and the length extension direction of the hook body and the depth extension direction of the slot are both parallel to the first diameter direction, and the hook body matches the size of the slot.

[0008] In some embodiments, shielding protrusions are further formed on the outer circumferential wall of the semicircular core segment, and the shielding protrusions are respectively arranged corresponding to the positions of the hook and the slot, and the shielding protrusions are located at both ends of the axial direction of the hook and the slot.

[0009] In some embodiments, the semicircular core segment comprises a first segment, a second segment and a third segment arranged in sequence along its axial direction, wherein the first segment and the third segment are both formed by stacking multiple first punching sheets, and the second segment is formed by stacking multiple second punching sheets.

[0010] In some embodiments, the axial length of the second segment is greater than the axial lengths of the first segment and the third segment, respectively; and / or, the axial lengths of the first segment and the third segment, respectively, are equal.

[0011] The present invention further provides a plastic-sealed stator assembly, comprising a stator core and an insulating frame coated on the outer wall of the stator core, wherein the stator core is the stator core described above.

[0012] In some embodiments, the insulating skeleton includes four skeleton splits, and a clip and a groove are formed on the end plate of each of the skeleton splits. The clip and the groove are respectively located on opposite sides of the end plate, and when the insulating skeleton and the stator core are assembled, the clip of one of the two skeleton splits at the same axial end of the stator core is buckled into the groove of the other one.

[0013] The present invention also provides a method for manufacturing the plastic-sealed stator assembly as described above, comprising the following steps:

[0014] Two semicircular core segment splits are manufactured, and the manufactured frame splits are respectively covered and connected to the semicircular core segment splits to form a first split component and a second split component respectively;

[0015] Winding stator windings on the first split component and the second split component respectively;

[0016] The first split assembly and the second split assembly wound with the stator winding are slidably plugged into one piece along the first diameter direction, and the buckles and grooves correspondingly arranged on the two skeleton splits at the same end of the semicircular core segment split are buckled to form a stator assembly;

[0017] The stator component is placed in an injection mold for plastic sealing to finally form the plastic-sealed stator assembly.

[0018] The present invention also provides a motor, comprising the above-mentioned plastic-sealed stator assembly.

[0019] The present invention also provides an air conditioner, comprising the above-mentioned motor.

[0020] The stator core, plastic-sealed stator assembly and manufacturing method thereof, motor and air conditioner provided by the present invention have the following beneficial effects:

[0021] The two semicircular core segments are separated by a transverse sliding limit structure located at the assembly surface position of the two. Since the transverse sliding limit structure is located in the middle area of ​​the axial length of the stator core, and the assembly direction of the two is a push-pull sliding direction along the first diameter of the stator core, and the sliding direction is parallel to the stacking gaps of the punching sheets of the semicircular core segment, the matching size of the transverse sliding limit structure can be smaller. In this way, after the two semicircular core segments are assembled, more reliable axial and radial limiting can be achieved, which is beneficial to prevent the stator core from being radially dislocated and offset due to the impact of the injection plastic during the subsequent plastic sealing process, thereby improving the concentricity of the stator assembly and helping to reduce the operating noise of the motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In order to more clearly illustrate the implementation methods of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for the implementation methods or the description of the prior art. The drawings described below are only exemplary, and for ordinary technicians in this field, other implementation drawings can be derived from the provided drawings without creative work.

[0023] Figure 1 It is a schematic diagram of the three-dimensional structure of the semicircular core segment split in the stator core of an embodiment of the present invention;

[0024] Figure 21 is a schematic diagram of a three-dimensional structure of a stator core in which two semicircular core segments are separately assembled into a full circle according to an embodiment of the present invention, wherein the arrow in the figure indicates the direction of sliding assembly;

[0025] Figure 3 yes Figure 1 Axial projection of the first punch in the first section and the third section;

[0026] Figure 4 yes Figure 1 An axial projection of the second punch in the third section;

[0027] Figure 5 is a schematic diagram of the three-dimensional structure of the frame split body in another embodiment of the present invention;

[0028] Figure 6 It is a schematic diagram of the three-dimensional structure after the semicircular core segment and the frame are assembled separately in an embodiment of the present invention;

[0029] Figure 7 is a schematic diagram of the three-dimensional structure of a stator assembly according to an embodiment of the present invention (stator windings are not shown);

[0030] Figure 8 is a schematic diagram of the three-dimensional structure of a stator assembly according to an embodiment of the present invention;

[0031] Fig. 9 It is a schematic diagram of the three-dimensional structure of the motor according to an embodiment of the present invention.

[0032] The accompanying drawings are marked as follows:

[0033] 1. Semicircular core segment split; 10. Assembly surface; 11. Buckle point; 21. Hook; 211. Hook body; 212. Connector; 22. Slot; 3. Shielding protrusion; 41. First segment; 42. Second segment; 43. Third segment; 51. First punching sheet; 52. Second punching sheet; 61. Split skeleton; 611. End plate; 612. Buckle; 613. Groove; 100. Stator core; 200. Insulating skeleton; 300. Rotor assembly. DETAILED DESCRIPTION

[0034] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments. The following description of at least one exemplary embodiment is actually only illustrative and is by no means intended to limit the present invention and its application or use. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0035] In the description of the present invention, it is necessary to understand that the directions or positional relationships indicated by directional words such as "front, back, up, down, left, right", "lateral, vertical, perpendicular, horizontal" and "top, bottom" are usually based on the directions or positional relationships shown in the drawings. They are only for the convenience of describing the present invention and simplifying the description. Unless otherwise specified, these directional words do not indicate or imply that the devices or elements referred to must have a specific direction or be constructed and operated in a specific direction. Therefore, they cannot be understood as limiting the scope of protection of the present invention. The directional words "inside and outside" refer to the inside and outside relative to the contours of each component itself.

[0036] For ease of description, spatially relative terms such as "above", "above", "on the upper surface of", "above", etc. may be used here to describe the spatial positional relationship between a device or feature and other devices or features as shown in the figure. It should be understood that spatially relative terms are intended to include different orientations of the device in use or operation in addition to the orientation described in the figure. For example, if the device in the accompanying drawings is inverted, the device described as "above other devices or structures" or "above other devices or structures" will be positioned as "below other devices or structures" or "below other devices or structures". Thus, the exemplary term "above" can include both "above" and "below". The device can also be positioned in other different ways (rotated 90° or in other orientations), and the spatially relative descriptions used here are interpreted accordingly.

[0037] In addition, it should be noted that the use of terms such as "first" and "second" to limit components is only for the convenience of distinguishing the corresponding components. If not otherwise stated, the above terms have no special meaning and therefore cannot be understood as limiting the scope of protection of the present invention.

[0038] See also Figure 1 and Fig. 9 According to an embodiment of the present invention, a stator core is provided. Figure 2 As shown, it includes two semicircular core segment splits 1, and the assembly surfaces 10 respectively provided by the two semicircular core segment splits 1 are fitted together to form a whole circle. The assembly surfaces 10 respectively provided by the two semicircular core segment splits 1 are spliced ​​by a transverse sliding limit structure (not marked in the figure), and the transverse sliding limit structure is located in the middle area of ​​the axial length of each semicircular core segment split 1, that is, the aforementioned transverse sliding limit structure is not provided at the axial ends of the semicircular core segment split 1, and the sliding and plugging direction of the transverse sliding limit structure is the first diameter direction of the stator core, and the aforementioned first diameter is, for example, Figure 2 In the direction indicated by the arrow in the figure, objectively, the first diameter direction is also the push-pull-slide to the left or right along a diameter direction of the stator core.

[0039] In this technical solution, the two semicircular core segment splits 1 are located at the assembly surface position of the two semicircular core segment splits. Since the transverse sliding limiting structure is located in the central area of ​​the axial length of the stator core, and the assembly direction of the two is a push-pull sliding direction along the first diameter of the stator core, and the sliding direction is parallel to the stacking gaps of the semicircular core segment splits 1, the matching size of the transverse sliding limiting structure can be smaller. In this way, after the two semicircular core segment splits 1 are assembled, more reliable axial and radial limiting can be achieved, which is beneficial to prevent the stator core from being radially displaced and offset due to the impact of the injection plastic during the subsequent plastic sealing process, thereby improving the concentricity of the stator assembly and helping to reduce the operating noise of the motor.

[0040] In some embodiments, see Figure 4 As shown, the lateral sliding limit structure includes a hook 21 formed on the first side circumferential wall of the semicircular core segment split 1 and a groove 22 formed on the second side circumferential wall of the semicircular core segment split 1, and the hook 21 protrudes from the assembly surface 10 of the semicircular core segment split 1, and the first side and the second side are symmetrical about the central axis of the stator core. When the two semicircular core segment splits 1 are spliced ​​into the full circle, the hook body 211 of the hook 21 of one semicircular core segment split 1 is embedded in the groove 22 of the other semicircular core segment split 1, that is, for the same semicircular core segment split 1, the aforementioned hook 21 and groove 22 thereon are respectively located on both sides of its assembly surface 10.

[0041] In this technical solution, the hook 21 is protruding from one side of the assembly surface 10, and the slot 22 is located on the other side of the assembly surface 10. When the two semicircular core segment splits 1 are assembled with each other, the two semicircular core segment splits 1 are symmetrical about the central axis of the stator core. After sliding horizontally in the direction of the aforementioned first diameter, the hooks 21 and slots 22 respectively possessed by the two semicircular core segment splits 1 are plugged into each other to form a limit in one direction of the left and right directions, thereby completing the assembly between the two.

[0042] See also Figure 4 As shown, in some embodiments, the hook 21 also has a connecting body 212 connected between the first side circumferential wall and the hook body 211, the connecting body 212 protrudes from the radially outer side of the first side circumferential wall, and the length extension direction of the hook body 211 and the depth extension direction of the slot 22 are both parallel to the first diameter direction, and the size of the hook body 211 matches that of the slot 22, that is, the shapes and sizes of the two are the same.

[0043] In this technical solution, the connector 212 of the hook 21 protrudes from the circumferential wall and does not occupy the area of ​​the mating surface of the two semicircular core segment splits 1, which can ensure the uniformity of the magnetic flux density in the yoke ring part of the assembled stator core as much as possible.

[0044] In some embodiments, a shielding protrusion 3 is further formed on the outer circumferential wall of the semicircular core segment split 1, and the shielding protrusion 3 is also protruding from the outer circumferential wall of the semicircular core segment split 1. The shielding protrusion 3 is respectively arranged corresponding to the position of the hook 21 and the slot 22, and the shielding protrusion 3 is located at both ends of the axial direction of the hook 21 and the slot 22. For details, see Figure 2 As shown, the aforementioned shielding protrusion 3 and the hook 21 and the slot 22 on the same side are arranged front and back in sequence along the axial direction of the stator core.

[0045] In this technical solution, by providing shielding protrusions 3 at both axial ends of the hook 21 and the slot 22, a certain support can be formed for the axial end surface of the hook 21, thereby ensuring the stability and reliability of the axial relative position of the assembled stator core.

[0046] In some embodiments, the semicircular core segment split 1 includes a first segment 41, a second segment 42 and a third segment 43 arranged in sequence along its axial direction, wherein the first segment 41 and the third segment 43 are both formed by stacking multiple first punching sheets 51, and the second segment 42 is formed by stacking multiple second punching sheets 52, and the first punching sheets 51 and the second punching sheets 52 are both provided with corresponding buckle points 11, and each first punching sheet 51 and / or second punching sheet 52 is reliably stacked with each other through the corresponding buckle points 11; in a preferred embodiment, the axial length of the second segment 42 is greater than the axial length of the first segment 41 and the third segment 43 respectively, so as to ensure the axial position reliability of the stator core and improve the structural strength of the stator core after splicing; and / or, the axial lengths of the first segment 41 and the third segment 43 are respectively equal, so as to ensure the consistency of the magnetic properties at the axial ends of the stator core.

[0047] According to an embodiment of the present invention, a plastic-encapsulated stator assembly is further provided, comprising a stator core 100 and an insulating frame 200 coated on the outer wall of the stator core 100, wherein the stator core 100 is the stator core described above. In a specific embodiment, the insulating frame 200 comprises four frame segments 61, each frame segment 61 having a completely identical design in structure, wherein two frame segments 61 are assembled to coat the upper half of the stator core 100 from one axial end thereof, and the remaining two frame segments 61 are assembled to coat the lower half of the stator core 100 from the other axial end thereof, for details, see Figure 5As shown, a buckle 612 and a groove 613 are formed on the end plate 611 of each of the frame splits 61, and the buckle 612 and the groove 613 are respectively located on the opposite sides of the end plate 611, and when the insulating frame 200 and the stator core 100 are assembled, the buckle 612 of one of the two frame splits 61 at the same axial end of the stator core 100 is buckled into the groove 613 of the other one. Generally speaking, each frame split 61 is generally made of plastic material, and the buckle 612, groove 613 and end plate 611 are integrally formed, and the buckle 612 has a certain elasticity. In actual application, the ends of the skeleton split 61 covering the upper half of the stator core 100 and the skeleton split 61 covering the lower half of the stator core 100 are mutually fitted to form an axial connection of the stator core 100, and the two skeleton splits 61 at the same axial end of the stator core 100 are reliably connected through the buckles 612 and grooves 613 respectively possessed by each other. The stator core 100 is fixed for the second time by the insulating skeleton 200, which can further improve the stator core's ability to resist impact and displacement during the injection molding process and ensure the roundness of the stator assembly.

[0048] It is understandable that the buckle 612 and the groove 613 should be completely matched in shape and size to ensure the position accuracy after the frame parts 61 are assembled.

[0049] According to an embodiment of the present invention, there is also provided a method for manufacturing the above-mentioned plastic-encapsulated stator assembly, comprising the following steps:

[0050] Two semicircular core segment split bodies 1 are manufactured, and the manufactured skeleton split bodies 61 are respectively covered and connected to the semicircular core segment split bodies 1 to form a first split body component (not labeled in the figure) and a second split body component (not labeled in the figure);

[0051] Winding stator windings (not shown in the figure) on the stator teeth of the first split component and the second split component respectively;

[0052] The first split assembly and the second split assembly wound with the stator winding are slidably plugged into one piece along the first diameter direction, and the buckles 612 and the grooves 613 correspondingly arranged on the two skeleton splits 61 at the same end of the semicircular core segment split 1 are buckled to form a stator assembly;

[0053] The stator component is placed in an injection mold for plastic sealing to finally form the plastic-sealed stator assembly.

[0054] In this technical solution, before the first split component and the second split component are assembled, the stator winding is first wound on the stator teeth of each split component, which makes winding more convenient and can also significantly improve the winding slot fill rate.

[0055] In some embodiments, the semicircular core segment 1 is manufactured in the following manner:

[0056] The first punching sheet 51 and the second punching sheet 52 are formed by stamping, and each of the first punching sheets 51 is stacked to form the first section 41 and the third section 43, and each of the second punching sheets 52 is stacked to form the second section 42. The first section 41, the second section 42 and the third section 43 are stacked from top to bottom along the axial direction to form a whole.

[0057] According to an embodiment of the present invention, a motor is further provided, in particular, a thyristor-controlled AC plastic-encapsulated motor, comprising the above-mentioned plastic-encapsulated stator assembly and rotor assembly 300. After the above-mentioned plastic-encapsulated stator assembly is manufactured, the rotor assembly 300 is further assembled, the Hall component and the end cover are installed, and the rubber ring is put on to complete the assembly of the entire motor.

[0058] According to an embodiment of the present invention, there is also provided an air conditioner, comprising the above-mentioned motor.

[0059] It is easy for those skilled in the art to understand that, without conflict, the advantageous technical features of the above-mentioned methods can be freely combined and superimposed.

[0060] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principle of the present invention shall be included in the protection scope of the present invention. The above description is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and variations can be made without departing from the technical principles of the present invention. These improvements and variations should also be regarded as the protection scope of the present invention.

Claims

1. A stator core, comprising two semicircular core segment parts (1), wherein the assembly surfaces (10) of the two semicircular core segment parts (1) are respectively attached to each other to form a full circle, characterized in that: The assembly surfaces (10) respectively provided by the two semicircular core segment split bodies (1) are spliced ​​together by a transverse sliding limit structure, the transverse sliding limit structure is located in the middle area of ​​the axial length of each semicircular core segment split body (1), and the sliding insertion direction of the transverse sliding limit structure is the first diameter direction of the stator core.

2. The stator core according to claim 1, characterized in that: The transverse sliding limit structure comprises a hook (21) formed on a first side circumferential wall of the semicircular core segment split (1) and a groove (22) formed on a second side circumferential wall of the semicircular core segment split (1), and the hook (21) protrudes from the assembly surface (10) of the semicircular core segment split (1), the first side and the second side are symmetrical about the central axis of the stator core, and when the two semicircular core segment splits (1) are assembled into the full circle, the hook body (211) of the hook (21) of one semicircular core segment split (1) is embedded in the groove (22) of the other semicircular core segment split (1).

3. The stator core according to claim 2, characterized in that: The hook (21) further comprises a connecting body (212) connected between the first side circumferential wall and the hook body (211); the connecting body (212) protrudes from the radially outer side of the first side circumferential wall; the length extension direction of the hook body (211) and the depth extension direction of the slot (22) are both parallel to the first diameter direction; the hook body (211) and the slot (22) have matching sizes.

4. The stator core according to claim 3, characterized in that: A shielding protrusion (3) is also formed on the outer circumferential wall of the semicircular core segment body (1), and the shielding protrusion (3) is arranged corresponding to the position of the hook (21) and the slot (22), and the shielding protrusion (3) is located at both ends of the axial direction of the hook (21) and the slot (22).

5. The stator core according to claim 4, characterized in that: The semicircular core segment split body (1) comprises a first segment (41), a second segment (42) and a third segment (43) which are sequentially arranged along the axial direction thereof, wherein the first segment (41) and the third segment (43) are both formed by stacking a plurality of first punching sheets (51), and the second segment (42) is formed by stacking a plurality of second punching sheets (52).

6. The stator core according to claim 5, characterized in that: The axial length of the second section (42) is greater than the axial lengths of the first section (41) and the third section (43), respectively; and / or the axial lengths of the first section (41) and the third section (43), respectively, are equal.

7. A plastic-sealed stator assembly, comprising a stator core (100) and an insulating frame (200) coated on the outer wall of the stator core (100), characterized in that: The stator core (100) is the stator core according to any one of claims 1 to 6.

8. The plastic-sealed stator assembly according to claim 7, characterized in that: The insulating frame (200) includes four frame segments (61), and a buckle (612) and a groove (613) are formed on the end plate (611) of each frame segment (61), and the buckle (612) and the groove (613) are respectively located on opposite sides of the end plate (611), and when the insulating frame (200) and the stator core (100) are assembled, the buckle (612) of one of the two frame segments (61) located at the same axial end of the stator core (100) is buckled into the groove (613) of the other frame segment.

9. A method for manufacturing a plastic-encapsulated stator assembly as claimed in claim 7 or 8, characterized in that: The steps include: Two semicircular core segment split bodies (1) are manufactured, and the manufactured skeleton split bodies (61) are respectively covered and connected to the semicircular core segment split bodies (1) to form a first split body component and a second split body component respectively; Winding stator windings on the first split component and the second split component respectively; The first split component and the second split component on which the stator winding is wound are slidably plugged into one piece along the first diameter direction, and the buckles (612) and grooves (613) correspondingly arranged on the two skeleton split components (61) at the same end of the semicircular iron core segment split component (1) are buckled to form a stator component; The stator component is placed in an injection mold for plastic sealing to finally form the plastic-sealed stator assembly.

10. A motor, characterized in that: It includes the plastic-sealed stator assembly as described in claim 7 or 8.

11. An air conditioner, characterized in that: The motor comprising the motor described in claim 10.

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