Motorcycle alternating current motor, alternating current motor stator assembly and preparation method thereof

Abstract

The invention relates to a motorcycle alternating current motor, an alternating current motor stator assembly and a preparation method thereof, the alternating current motor stator assembly comprises a stator main body, the outer side wall of the stator main body is provided with a plurality of winding teeth, and a winding groove is arranged between two adjacent winding teeth; the winding teeth comprise a charging ignition coil winding tooth and a plurality of charging illumination coil winding teeth; an arc-shaped pole shoe is arranged at the top of each winding tooth, and arc-shaped baffles are arranged on the two side edges of each pole shoe; the outer side wall of the stator body, the outer walls of the winding teeth, the inner side walls of the pole shoes and the inner side walls of the baffles are all covered with insulating layers, and the insulating layers are fixedly provided with charging ignition coil leading-out heads and charging lighting coil clamping piece clamping grooves. Only one charging ignition coil winding tooth is arranged, only one charging ignition coil needs to be arranged in the manufacturing process, the winding workload is reduced, and the production efficiency is improved.

Description

Technical Field

[0001] The invention belongs to the field of motors, and in particular to an AC motor for a motorcycle, an AC motor stator assembly and a preparation method thereof. Background Art

[0002] The stator of the motorcycle AC motor is usually equipped with a charging ignition coil and a charging lighting coil. The charging ignition coil is used to provide low-voltage electricity for ignition to the igniter, and the charging lighting coil is used to provide power to the motorcycle headlights and charge the battery at the same time. The CG125 series motor is a commonly used AC motor for motorcycles. Two identical charging ignition coils are set on its stator. The two poles need to be wound twice during manufacturing, which affects efficiency. In addition, the charging ignition coil and the charging lighting coil need to be connected to the lead wire through a lead or a card, and then connected to the external components by the lead wire. However, the stator of the existing CG125 series motor does not have a fixed-position lead. The lead needs to be temporarily set during manufacturing, which is difficult to produce and process, affecting efficiency. And because the relative position of the lead and the coil is difficult to keep fixed, the position of the lead on different stators relative to the coil is different, and the motor performance is difficult to unify, affecting the product qualification rate. Summary of the invention

[0003] The technical problem to be solved by the present invention is to provide a motorcycle AC motor, an AC motor stator assembly and a preparation method thereof, so as to improve production efficiency and motor quality.

[0004] To solve the above problems, the technical solution adopted by the present invention is: an AC motor stator assembly, comprising a stator body, wherein the outer wall of the stator body is provided with a plurality of winding teeth, and a winding groove is provided between two adjacent winding teeth;

[0005] The winding teeth include a charging ignition coil winding tooth and a plurality of charging lighting coil winding teeth;

[0006] An arc-shaped pole shoe is arranged on the top of each winding tooth, and arc-shaped baffles are arranged on both sides of the pole shoe;

[0007] The outer wall of the stator body, the outer wall of the winding teeth, the inner wall of the pole shoe and the inner wall of the baffle are all covered with an insulating layer, and the charging ignition coil lead-out head and the charging lighting coil card slot are fixedly arranged on the insulating layer.

[0008] Furthermore, the insulating layer includes a first insulating end cover and a second insulating end cover, each of which includes an integrally formed center sleeve, a winding tooth groove arranged on the outer wall of the center sleeve, and a baffle cover arranged on the top of the winding tooth groove, the stator body and the winding teeth are inserted into the first insulating end cover and the second insulating end cover, and the ports of the first insulating end cover and the second insulating end cover abut against each other, so that the center sleeve covers the outer wall of the stator body, the winding tooth groove covers the outer wall of the winding tooth, and the baffle cover covers the inner wall of the pole shoe and the baffle.

[0009] Furthermore, the charging ignition coil lead-out head is fixedly arranged on the outer side wall of the first insulating end cover, the charging lighting coil card connector slot is arranged on the outer side wall of the second insulating end cover, and the charging lighting coil card connector slot is integrally formed with the second insulating end cover.

[0010] Furthermore, the first insulating end cover and the second insulating end cover are plastic covers.

[0011] Furthermore, the outer side wall of the baffle is exposed, and the outer side wall of the baffle and the outer side wall of the pole shoe are located on the same cylindrical surface.

[0012] The motorcycle AC motor comprises a rotor and a stator arranged inside the rotor, wherein the stator adopts the AC motor stator assembly.

[0013] The method for preparing the AC motor stator assembly comprises the following steps:

[0014] S1. Prepare a stator body, wherein the outer wall of the stator body is provided with a plurality of winding teeth, and a winding groove is provided between two adjacent winding teeth, wherein the winding teeth include a charging ignition coil winding tooth and a plurality of charging lighting coil winding teeth; an arc-shaped pole shoe is provided on the top of each winding tooth, and arc-shaped baffles are provided on both sides of the pole shoe;

[0015] S2. An insulating layer is provided on the outer wall of the stator body, the outer wall of the winding teeth, the inner wall of the pole shoe and the inner wall of the baffle. The charging lighting coil card slot is integrally formed with the insulating layer, and one end of the charging ignition coil lead is buried in the insulating layer, and the other end is exposed;

[0016] S3, winding the charging ignition coil on the charging ignition coil winding teeth, and winding the charging lighting coil on the charging lighting coil winding teeth;

[0017] S4. Solder the lead-out terminal of the charging ignition coil to the lead-out head of the charging ignition coil, insert the card connector of the charging lighting coil into the card connector slot of the charging lighting coil, and card-connect the lead-out terminal of the charging lighting coil to the card connector.

[0018] Furthermore, in step S2, a first insulating end cover and a second insulating end cover are prepared by a molding process, and then the prepared first insulating end cover and the second insulating end cover are respectively sleeved on the stator body from both ends of the stator body, and the opening ends of the first insulating end cover and the second insulating end cover are abutted, so that the first insulating end cover and the second insulating end cover cover the outer wall of the stator body, the outer wall of the winding teeth, the inner wall of the pole shoe and the inner wall of the baffle.

[0019] The beneficial effects of the present invention are as follows: 1. The present invention only has one charging ignition coil winding tooth. During manufacturing, only one charging ignition coil needs to be set, the winding workload is reduced, and the production efficiency is improved.

[0020] 2. The present invention sets the charging ignition coil lead and the charging lighting coil card slot at a fixed position, so that in each motor, the charging ignition coil lead is fixed relative to the charging ignition coil, and the charging lighting coil card slot is fixed relative to the charging lighting coil, which ensures the uniformity of motor performance and is conducive to improving the qualified rate. In addition, there is no need to temporarily set the charging ignition coil lead and the charging lighting coil card slot, which reduces the production difficulty and is conducive to improving production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is a schematic diagram of the AC motor stator assembly before the insulation layer is provided;

[0022] Figure 2 It is a schematic diagram of an end face of the stator assembly of the AC motor of the present invention after an insulating layer is provided;

[0023] Figure 3 It is another end face schematic diagram of the AC motor stator assembly after the insulation layer is provided;

[0024] Figure 4 is a schematic diagram of the inner side of the first insulating end cover;

[0025] Figure 5 is a schematic diagram of the outer side of the first insulating end cover;

[0026] Figure 6 is a schematic diagram of the inner side of the second insulating end cover;

[0027] Figure 7 is a schematic diagram of the outer side of the second insulating end cover;

[0028] Figure 8 It is a radial cross-sectional schematic diagram of the stator assembly of the AC motor of the present invention;

[0029] Fig. 9 Schematic diagram of radial section of the AC motor for motorcycle of the present invention;

[0030] Figure numerals: 1—stator body; 2—winding teeth; 21—charging ignition coil winding teeth; 22—charging lighting coil winding teeth; 23—pole shoe; 24—baffle; 3—winding groove; 4—insulating layer; 41—charging ignition coil lead-out head; 42—charging lighting coil card slot; 43—first insulating end cover; 44—second insulating end cover; 45—center sleeve; 46—winding tooth groove; 47—baffle cover; 10—rotor. DETAILED DESCRIPTION

[0031] The present invention is further described below in conjunction with the accompanying drawings and embodiments.

[0032] The AC motor stator assembly of the present invention is as follows Figures 1 to 8 As shown, it comprises a stator body 1 , a plurality of winding teeth 2 are arranged on the outer wall of the stator body 1 , and a winding groove 3 is arranged between two adjacent winding teeth 2 .

[0033] The winding teeth 2 include a charging ignition coil winding tooth 21 and a plurality of charging lighting coil winding teeth 22. The charging ignition coil winding tooth 2 is used to wind the charging ignition coil, and the charging lighting coil winding tooth 22 is used to wind the charging lighting coil. The present invention only has one charging ignition coil winding tooth 21, and during manufacturing, only one charging ignition coil needs to be set, which reduces the workload of winding and improves production efficiency.

[0034] An arc-shaped pole shoe 23 is arranged on the top of each winding tooth 2, and arc-shaped baffles 24 are arranged on both sides of the pole shoe 23. The baffles 24 are used to limit the coil and improve the stability of the coil.

[0035] The charging ignition coil and the charging lighting coil are made of enameled wire, and the stator body 1, winding teeth 2, pole shoes 23 and baffle 24 are made of metal. Since the insulating paint on the surface of the enameled wire is relatively thin, leakage may occur after wear, so it is usually necessary to insulate the parts that contact the coil. Specifically, the outer wall of the stator body 1, the outer wall of the winding teeth 2, the inner wall of the pole shoes 23 and the inner wall of the baffle 24 are all covered with an insulating layer 4, which plays a role in preventing leakage. The charging ignition coil lead-out head 41 and the charging lighting coil card slot 42 are fixedly arranged on the insulating layer 4. The charging ignition coil lead-out head 41 is used to connect the charging ignition coil and the lead-out wire. Specifically, the charging ignition coil lead-out head 41 is made of a conductive metal sheet. After the charging ignition coil is wound, the lead-out end of the charging ignition coil and the end of the lead-out wire can be soldered to the charging ignition coil lead-out head 41. The charging lighting coil card slot 42 is used to card the charging lighting coil card slot. The charging lighting coil card slot is a metal sheet. Specifically, the charging lighting coil card slot 42 can be a rectangular slot, and the card slot can be interference fit with the rectangular slot. After the charging lighting coil is wound, the card slot can be inserted into the charging lighting coil card slot 42, and then the lead-out end of the charging lighting coil is connected to the card slot.

[0036] In the present invention, the charging ignition coil lead 41 and the charging lighting coil card slot 42 can be fixed to the insulating layer 4 while preparing the insulating layer 4. By fixing the positions of the charging ignition coil lead 41 and the charging lighting coil card slot 42, the position of the charging ignition coil lead 41 relative to the charging ignition coil is fixed in each motor, and the position of the charging lighting coil card slot 42 relative to the charging lighting coil is fixed, thereby ensuring uniform motor performance and facilitating improving the qualified rate. In addition, there is no need to temporarily set the charging ignition coil lead 41 and the charging lighting coil card slot 42, thereby reducing the production difficulty and facilitating improving the production efficiency.

[0037] The conventional insulating layer 4 is usually formed by injection molding, that is, the stator body 1 is placed in a mold as a whole, and then molten plastic is introduced into the mold, and the plastic is demolded after cooling to obtain the insulating layer 4. Since the insulating layer 4 does not need to be provided on the entire surface of the stator core, for example, the two end surfaces of the stator body 1 and the outer side wall of the pole shoe 23 cannot be provided with the insulating layer 4, the mold structure is relatively complex, the cost is high, and it is difficult to perform mass injection molding.

[0038] In order to facilitate obtaining the insulating layer 4, the insulating layer 4 of the present invention includes a first insulating end cover 43 and a second insulating end cover 44. The first insulating end cover 43 and the second insulating end cover 44 both include an integrally formed center sleeve 45, a winding tooth groove 46 arranged on the outer wall of the center sleeve 45, and a baffle cover 47 arranged on the top of the winding tooth groove 46. The shape and size of the center sleeve 45 are adapted to the outer shape and size of the stator body 1, the shape and size of the winding tooth groove 46 are adapted to the shape and size of the winding tooth 2, and the shape and size of the baffle cover 47 are adapted to the shape and size of the inner wall of the pole shoe 23 and the baffle 24. The stator body 1 and the winding teeth 2 are inserted into the first insulating end cover 43 and the second insulating end cover 44. Specifically, the stator body 1 is inserted into the center sleeve 45, the winding teeth 2 are inserted into the winding tooth grooves 46, and the ports of the first insulating end cover 43 and the second insulating end cover 44 abut against each other, so that the center sleeve 45 covers the outer wall of the stator body 1, the winding tooth grooves 46 cover the outer wall of the winding teeth 2, and the baffle cover 47 covers the inner wall of the pole shoe 23 and the baffle 24.

[0039] The first insulating end cover 43 and the second insulating end cover 44 may be plastic covers, which may be formed by a molding process. The first insulating end cover 43 and the second insulating end cover 44 have a certain elasticity. After the stator body 1 and the winding teeth 2 are inserted into the first insulating end cover 43 and the second insulating end cover 44, the first insulating end cover 43 and the second insulating end cover 44 are stably sleeved on the stator body 1 and the winding teeth 2 by utilizing the elasticity of the first insulating end cover 43 and the second insulating end cover 44.

[0040] The first insulating cover 61 and the second insulating cover 62 can be mass-produced by a molding process, which is very convenient and quick to install, and is beneficial to improving the production efficiency of the AC stator core.

[0041] The charging ignition coil lead-out terminal 41 is fixedly arranged on the outer side wall of the first insulating end cover 43. When forming the first insulating end cover 43, one end of the charging ignition coil lead-out terminal 41 can be extended into the cavity of the forming mold, and the other end can be located outside the cavity. Then, the molten plastic is injected into the cavity of the mold, and the mold is demolded after the plastic is cooled and solidified, thereby obtaining the first insulating end cover 43 with the charging ignition coil lead-out terminal 41.

[0042] The charging lighting coil card connector slot 42 is arranged on the outer side wall of the second insulating end cover 44 . The charging lighting coil card connector slot 42 is made of plastic material, and the charging lighting coil card connector slot 42 and the second insulating end cover 44 are integrally formed.

[0043] In the present invention, the outer side wall of the baffle 24 is exposed, and the outer side wall of the baffle 24 and the outer side wall of the pole piece 23 are located on the same cylindrical surface.

[0044] In a traditional AC stator core, the insulating layer 4 covers the inner and outer walls of the baffle 24. Since the insulating layer 4 on the outer wall of the baffle 24 has a certain thickness, the outer diameter of the baffle 24 is smaller than the outer diameter of the pole shoe 23. After the stator and the rotor are assembled, the radial distance from the baffle 24 to the rotor is greater than the radial distance from the pole shoe 23 to the rotor. Therefore, the air gap between the baffle 24 and the rotor is larger and the magnetic flux is smaller. Therefore, it is necessary to set an enameled wire with a large number of turns on the winding column 2 to meet the electromotive force requirements. The cost of the stator core is high and the weight is also large.

[0045] In the present invention, since the outer wall of the baffle 24 is not provided with an insulating layer 4, the outer wall of the baffle 24 and the outer wall of the pole shoe 23 can be located on the same cylindrical surface. After the rotor and the stator are assembled, the radial air gap between the baffle 24 and the inner arc of the rotor pole is reduced, so the magnetic flux will also increase.

[0046] In addition, in the conventional AC stator core, the baffle 24 is covered by the insulating layer 4, and the magnetic field is mainly conducted through the pole shoe 23. In the present invention, the outer wall of the baffle 24 is moved outward and exposed, so that the outer wall of the baffle 24 and the outer wall of the pole shoe 23 are located on the same cylindrical surface. The baffle 24 and the pole shoe 23 conduct magnetic field at the same time, and the magnetic field area is increased, thereby increasing the magnetic flux.

[0047] The more turns of enameled wire on the winding teeth 2, the greater the electromotive force. Under the condition of the same number of turns of enameled wire, the magnetic flux of the AC stator core of the present invention exceeds the magnetic flux of the prior art, so the present invention can achieve the same electromotive force with fewer turns of enameled wire. After the number of turns of enameled wire is reduced, the manufacturing cost of the AC stator core is reduced, and the weight is also reduced.

[0048] The motorcycle AC motor of the present invention is as follows Fig. 9 As shown, the invention comprises a rotor 10 and a stator arranged inside the rotor 10. The stator adopts Figures 1 to 8 The AC motor stator assembly is shown.

[0049] The method for preparing the stator assembly of an AC motor of the present invention comprises the following steps:

[0050] S1. Prepare a stator body 1. The outer wall of the stator body 1 is provided with a plurality of winding teeth 2. A winding groove 3 is provided between two adjacent winding teeth 2. The winding teeth 2 include a charging ignition coil winding tooth 21 and a plurality of charging lighting coil winding teeth 22. The top of each winding tooth 2 is provided with an arc-shaped pole shoe 23. Both sides of the pole shoe 23 are provided with arc-shaped baffles 24. This step can be performed using the existing technology.

[0051] S2. An insulating layer 4 is set on the outer wall of the stator body 1, the outer wall of the winding teeth 2, the inner wall of the pole shoe 23 and the inner wall of the baffle 24. The charging lighting coil card slot 42 is integrally formed with the insulating layer 4, and one end of the charging ignition coil lead-out head 41 is buried in the insulating layer 4, and the other end is exposed.

[0052] Specifically, the insulating layer 4 of plastic material can be obtained by traditional injection molding. In order to improve production efficiency, the first insulating end cover 43 and the second insulating end cover 44 are prepared by molding process, and then the prepared first insulating end cover 43 and the second insulating end cover 44 are respectively sleeved on the stator body 1 from both ends, and the open ends of the first insulating end cover 43 and the second insulating end cover 44 are abutted, so that the first insulating end cover 43 and the second insulating end cover 44 cover the outer wall of the stator body 1, the outer wall of the winding tooth 2, the inner wall of the pole shoe 23 and the inner wall of the baffle 24.

[0053] S3, winding the charging ignition coil on the charging ignition coil winding teeth 21, and winding the charging lighting coil on the charging lighting coil winding teeth 22;

[0054] S4. Solder the lead-out end of the charging ignition coil to the charging ignition coil lead-out head 41, insert the card connector of the charging lighting coil into the charging lighting coil card connector slot 42, and card-connect the lead-out end of the charging lighting coil to the card connector.

[0055] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. An AC motor stator assembly, comprising a stator body (1), wherein the outer wall of the stator body (1) is provided with a plurality of winding teeth (2), and a winding groove (3) is provided between two adjacent winding teeth (2); characterized in that: The winding teeth (2) include a charging ignition coil winding tooth (21) and a plurality of charging lighting coil winding teeth (22); An arc-shaped pole shoe (23) is arranged at the top of each winding tooth (2), and arc-shaped baffles (24) are arranged on both sides of the pole shoe (23); The outer wall of the stator body (1), the outer wall of the winding teeth (2), the inner wall of the pole shoe (23) and the inner wall of the baffle (24) are all covered with an insulating layer (4), and a charging ignition coil lead-out head (41) and a charging lighting coil card slot (42) are fixedly arranged on the insulating layer (4).

2. The AC motor stator assembly according to claim 1, characterized in that: The insulating layer (4) comprises a first insulating end cover (43) and a second insulating end cover (44), wherein the first insulating end cover (43) and the second insulating end cover (44) both comprise an integrally formed center sleeve (45), a winding tooth groove (46) arranged on the outer wall of the center sleeve (45), and a baffle cover (47) arranged on the top of the winding tooth groove (46); the stator body (1) and the winding teeth (2) are plugged into the first insulating end cover (43) and the second insulating end cover (44), and the ports of the first insulating end cover (43) and the second insulating end cover (44) are mutually abutted, so that the center sleeve (45) covers the outer wall of the stator body (1), the winding tooth groove (46) covers the outer wall of the winding teeth (2), and the baffle cover (47) covers the inner wall of the pole shoe (23) and the baffle (24).

3. The AC motor stator assembly according to claim 2, characterized in that: The charging ignition coil lead-out terminal (41) is fixedly arranged on the outer side wall of the first insulating end cover (43), the charging lighting coil card connector slot (42) is arranged on the outer side wall of the second insulating end cover (44), and the charging lighting coil card connector slot (42) and the second insulating end cover (44) are integrally formed.

4. The AC motor stator assembly according to claim 2, characterized in that: The first insulating end cover (43) and the second insulating end cover (44) are plastic covers.

5. The AC motor stator assembly according to claim 1, characterized in that: The outer side wall of the baffle (24) is exposed, and the outer side wall of the baffle (24) and the outer side wall of the pole shoe (23) are located on the same cylindrical surface.

6. A motorcycle AC motor, comprising a rotor (10) and a stator arranged inside the rotor (10), characterized in that: The stator adopts the AC motor stator assembly according to any one of claims 1 to 5.

7. The method for preparing the AC motor stator assembly according to any one of claims 1 to 6, characterized in that: The following steps are involved: S1. Prepare a stator body (1), wherein the outer wall of the stator body (1) is provided with a plurality of winding teeth (2), a winding groove (3) is provided between two adjacent winding teeth (2), and the winding teeth (2) include a charging ignition coil winding tooth (21) and a plurality of charging lighting coil winding teeth (22); an arc-shaped pole shoe (23) is provided at the top of each winding tooth (2), and arc-shaped baffles (24) are provided on both sides of the pole shoe (23); S2, an insulating layer (4) is provided on the outer wall of the stator body (1), the outer wall of the winding teeth (2), the inner wall of the pole shoe (23), and the inner wall of the baffle (24); the charging lighting coil card slot (42) is integrally formed with the insulating layer (4); one end of the charging ignition coil lead (41) is buried in the insulating layer (4), and the other end is exposed; S3, winding the charging ignition coil on the charging ignition coil winding teeth (21), and winding the charging lighting coil on the charging lighting coil winding teeth (22); S4. Solder the lead-out end of the charging ignition coil to the charging ignition coil lead-out head (41), insert the card connector of the charging lighting coil into the charging lighting coil card connector slot (42), and card-connect the lead-out end of the charging lighting coil to the card connector.

8. The method for preparing the AC motor stator assembly according to claim 7, characterized in that: In step S2, a first insulating end cover (43) and a second insulating end cover (44) are prepared by a molding process, and then the prepared first insulating end cover (43) and the second insulating end cover (44) are respectively sleeved on the stator body (1) from both ends of the stator body (1), and the opening ends of the first insulating end cover (43) and the second insulating end cover (44) are abutted, so that the first insulating end cover (43) and the second insulating end cover (44) cover the outer wall of the stator body (1), the outer wall of the winding tooth (2), the inner wall of the pole shoe (23) and the inner wall of the baffle (24).

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