Motorcycle alternator, alternator stator assembly and method of making same

Abstract

The present application relates to a motorcycle AC motor, AC motor stator assembly and its preparation method, the AC motor stator assembly includes the stator main body, the stator main body outer wall is provided with a plurality of winding teeth, and winding slot is arranged between the adjacent two winding teeth;The winding tooth includes a charging ignition coil winding tooth and a plurality of charging lighting coil winding tooth;The top of each winding tooth is provided with an arc-shaped pole shoe, and the two side edges of the pole shoe are provided with arc-shaped baffles;The outer wall of the stator main body, the outer wall of the winding tooth, the inner side wall of the pole shoe and the inner side wall of the baffle are all covered with an insulating layer, and the insulating layer is fixedly provided with a charging ignition coil lead-out head and a charging lighting coil clamping piece clamping groove.The present application only sets up a charging ignition coil winding tooth, and only needs to set up a charging ignition coil when manufacturing, so that the winding workload is reduced, and the production efficiency is improved.

Description

TECHNICAL FIELD

[0001] The present application belongs to the field of electric machines, in particular to a motorcycle alternating current motor, an alternating current motor stator assembly and a preparation method thereof. BACKGROUND

[0002] The stator of a motorcycle alternating current motor is usually provided with a charging ignition coil and a charging lighting coil, wherein the charging ignition coil is used to provide low-voltage electricity for the igniter, and the charging lighting coil is used to provide electricity for the motorcycle headlamp and charge the battery. The CG125 series motor is a commonly used alternating current motor for motorcycles, and two identical charging ignition coils are provided on the stator thereof, which requires winding two poles twice during manufacturing, affecting the efficiency. In addition, the charging ignition coil and the charging lighting coil need to be connected to the lead wire through the lead-out head or the clamping piece, and then connected to the external element through the lead wire. However, the stator of the existing CG125 series motor does not have a fixed position lead-out head, and the lead-out head needs to be temporarily set during manufacturing, which is difficult to produce and process, affecting the efficiency. Moreover, since the relative position of the lead-out head and the coil is difficult to keep fixed, the position of the lead-out head relative to the coil on different stators is different, the performance of the motor is difficult to unify, and the qualified rate of the product is affected. SUMMARY

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

[0004] To solve the above problems, the technical scheme adopted by the present application is as follows: an alternating current motor stator assembly, comprising a stator main body, a plurality of winding teeth are arranged on the outer side wall of the stator main body, and a winding slot is arranged between adjacent two winding teeth;

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

[0006] The top of each winding tooth is provided with an arc-shaped pole shoe, and the two side edges of the pole shoe are provided with arc-shaped baffles;

[0007] The outer side wall of the stator main body, the outer wall of the winding tooth, the inner side wall of the pole shoe and the inner side wall of the baffle are all covered with an insulating layer, and the insulating layer is fixedly provided with a charging ignition coil lead-out head and a charging lighting coil clamping piece clamping groove.

[0008] Further, the insulation layer comprises a first insulation end cover and a second insulation end cover, each of the first insulation end cover and the second insulation end cover comprises an integrally formed central sleeve, a winding tooth slot arranged on the outer wall of the central sleeve, and a baffle cover arranged on the top of the winding tooth slot, the stator body and the winding teeth are inserted into the first insulation end cover and the second insulation end cover, and the ports of the first insulation end cover and the second insulation end cover abut each other, so that the central sleeve covers the outer sidewall of the stator body, the winding tooth slot covers the outer wall of the winding teeth, and the baffle cover covers the inner sidewall of the pole shoe and the baffle.

[0009] Further, the charging ignition coil lead-out head is fixedly arranged on the outer sidewall of the first insulation end cover, the charging illumination coil clamping piece clamping groove is arranged on the outer sidewall of the second insulation end cover, and the charging illumination coil clamping piece clamping groove is integrally formed with the second insulation end cover.

[0010] Further, the first insulation end cover and the second insulation end cover are plastic covers.

[0011] Further, the outer sidewall of the baffle is exposed, and the outer sidewall of the baffle is located on the same cylindrical surface as the outer sidewall of the pole shoe.

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

[0013] The preparation method of the alternating current motor stator assembly comprises the following steps:

[0014] S1, preparing a stator body, the outer sidewall of the stator body is provided with a plurality of winding teeth, a winding slot is arranged between adjacent two winding teeth, the winding teeth comprise a charging ignition coil winding tooth and a plurality of charging illumination coil winding teeth; the top of each winding tooth is provided with an arc-shaped pole shoe, and the two side edges of the pole shoe are provided with arc-shaped baffles;

[0015] S2, arranging an insulation layer on the outer sidewall of the stator body, the outer wall of the winding teeth, the inner sidewall of the pole shoe, and the inner sidewall of the baffle, the charging illumination coil clamping piece clamping groove is integrally formed with the insulation layer, and one end of the charging ignition coil lead-out head is embedded in the insulation layer, and the other end is exposed;

[0016] S3, winding the charging ignition coil on the charging ignition coil winding tooth, and winding the charging illumination coil on the charging illumination coil winding tooth;

[0017] S4, tin soldering the lead-out end of the charging ignition coil to the charging ignition coil lead-out head, inserting the clamping piece of the charging illumination coil into the charging illumination coil clamping piece clamping groove, and clamping the lead-out end of the charging illumination coil to the clamping piece.

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

[0019] The beneficial effects of the present application are: 1. The present application only sets one charging ignition coil winding tooth, and only needs to set one charging ignition coil during manufacturing, thereby reducing the winding workload and improving the production efficiency.

[0020] 2. The present application sets the charging ignition coil lead-out head and the charging lighting coil clamping piece clamping groove in a fixed position, so that the position of the charging ignition coil lead-out head relative to the charging ignition coil is fixed, and the position of the charging lighting coil clamping piece clamping groove relative to the charging lighting coil is fixed in each motor, thereby ensuring the uniformity of the motor performance and being conducive to improving the qualified rate. In addition, the charging ignition coil lead-out head and the charging lighting coil clamping piece clamping groove do not need to be temporarily set, thereby reducing the production difficulty and being conducive to improving the production efficiency. BRIEF DESCRIPTION OF DRAWINGS

[0021] Figure 1 is a schematic diagram of the stator assembly of the alternating current motor before the insulating layer is set in the present application;

[0022] Figure 2 is a schematic diagram of one end surface after the insulating layer is set in the stator assembly of the alternating current motor in the present application;

[0023] Figure 3 is a schematic diagram of another end surface after the insulating layer is set in the stator assembly of the alternating current motor in the present application;

[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 is a schematic diagram of the radial cross section of the stator assembly of the alternating current motor in the present application;

[0029] Figure 9 is a schematic diagram of the radial cross section of the motorcycle alternating current motor in the present application;

[0030] Reference 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—Insulation layer; 41—Charging ignition coil lead-out head; 42—Charging lighting coil snap-fit ​​slot; 43—First insulating end cover; 44—Second insulating end cover; 45—Center sleeve; 46—Winding tooth groove; 47—Baffle cover; 10—Rotor. Detailed Implementation

[0031] The present invention will be further described below with reference to the accompanying drawings and embodiments.

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

[0033] The winding tooth 2 includes one charging ignition coil winding tooth 21 and multiple charging lighting coil winding teeth 22. The charging ignition coil winding tooth 21 is used to wind the charging ignition coil, and the charging lighting coil winding teeth 22 are used to wind the charging lighting coil. This invention only provides one charging ignition coil winding tooth 21. During manufacturing, only one charging ignition coil needs to be provided, reducing the amount of winding work and improving production efficiency.

[0034] Each winding tooth 2 has an arc-shaped pole shoe 23 at its top, and arc-shaped baffles 24 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 adopt enameled wire, the stator body 1, the winding tooth 2, the pole shoe 23 and the baffle 24 adopt metal material, because the thickness of the insulating paint on the surface of the enameled wire is low, and after wearing, it may leak electricity, therefore, generally, the parts contacting the coil need to be insulated, specifically, the outer side wall of the stator body 1, the outer wall of the winding tooth 2, the inner side wall of the pole shoe 23 and the inner side wall of the baffle 24 are covered with an insulating layer 4, which prevents leakage. The charging ignition coil lead-out head 41 and the charging lighting coil clamping piece clamping groove 42 are fixedly arranged on the insulating layer 4. The charging ignition coil lead-out head 41 is used for connecting the charging ignition coil and the lead-out wire, specifically, the charging ignition coil lead-out head 41 adopts a conductive metal sheet, after winding the charging ignition coil, 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 clamping piece clamping groove 42 is used for clamping the charging lighting coil clamping piece, which is a metal sheet, specifically, the charging lighting coil clamping piece clamping groove 42 can be a rectangular groove, and the clamping piece can be interference-fitted with the rectangular groove. After winding the charging lighting coil, the clamping piece can be inserted into the charging lighting coil clamping piece clamping groove 42, and then the lead-out end of the charging lighting coil is connected with the clamping piece.

[0036] In the present application, the charging ignition coil lead-out head 41 and the charging lighting coil clamping piece clamping groove 42 can be fixed on the insulating layer 4 at the same time as the insulating layer 4 is prepared, by fixing the positions of the charging ignition coil lead-out head 41 and the charging lighting coil clamping piece clamping groove 42, the position of the charging ignition coil lead-out head 41 relative to the charging ignition coil is fixed, and the position of the charging lighting coil clamping piece clamping groove 42 relative to the charging lighting coil is fixed in each motor, which ensures the uniformity of motor performance and helps to improve the pass rate. In addition, the charging ignition coil lead-out head 41 and the charging lighting coil clamping piece clamping groove 42 do not need to be temporarily arranged, which reduces the production difficulty and helps to improve the production efficiency.

[0037] The traditional insulating layer 4 is usually injection molded, that is, the stator body 1 is put into the mold as a whole, then molten plastic is introduced into the mold, and after the plastic cools, the mold is demolded, and the insulating layer 4 is obtained. Because the insulating layer 4 does not need to be arranged on the entire surface of the stator core, for example, the insulating layer 4 cannot be arranged on the end faces of the stator body 1 and the outer side wall of the pole shoe 23, therefore, the mold structure is relatively complex, the cost is high, and it is difficult to mass-produce by injection molding.

[0038] In order to facilitate obtaining the insulation layer 4, the insulation layer 4 of the application comprises a first insulation end cover 43 and a second insulation end cover 44, the first insulation end cover 43 and the second insulation end cover 44 each comprise an integrally formed center sleeve 45, wire winding tooth grooves 46 arranged on the outer wall of the center sleeve 45, and baffle covers 47 arranged on the top of the wire winding tooth grooves 46, the shape and size of the center sleeve 45 are adapted to the shape and size of the stator body 1, the shape and size of the wire winding tooth grooves 46 are adapted to the shape and size of the wire winding teeth 2, and the shape and size of the baffle covers 47 are adapted to the shape and size of the inner side wall of the pole shoes 23 and the baffles 24. The stator body 1 and the wire winding teeth 2 are inserted into the first insulation end cover 43 and the second insulation end cover 44, specifically, the stator body 1 is inserted into the center sleeve 45, the wire winding teeth 2 are inserted into the wire winding tooth grooves 46, and the ports of the first insulation end cover 43 and the second insulation end cover 44 abut each other, so that the center sleeve 45 covers the outer side wall of the stator body 1, the wire winding tooth grooves 46 cover the outer wall of the wire winding teeth 2, and the baffle covers 47 cover the inner side wall of the pole shoes 23 and the baffles 24.

[0039] The first insulation end cover 43 and the second insulation end cover 44 can be plastic covers and can be formed by a molding process. The first insulation end cover 43 and the second insulation end cover 44 have a certain elasticity, and after the stator body 1 and the wire winding teeth 2 are inserted into the first insulation end cover 43 and the second insulation end cover 44, the elasticity of the first insulation end cover 43 and the second insulation end cover 44 is used to stably sleeve the first insulation end cover 43 and the second insulation end cover 44 on the stator body 1 and the wire winding teeth 2.

[0040] The first insulation cover 61 and the second insulation cover 62 can be mass-produced by a molding process, which is very convenient and fast during installation and is conducive to improving the production efficiency of the alternating current stator core.

[0041] The charging ignition coil lead-out head 41 is fixedly arranged on the outer side wall of the first insulation end cover 43. When the first insulation end cover 43 is formed, one end of the charging ignition coil lead-out head 41 is inserted into a cavity of a forming mold, and the other end is located outside the cavity. Then, molten plastic is injected into the cavity of the mold. After the plastic is cooled and solidified, the first insulation end cover 43 with the charging ignition coil lead-out head 41 is obtained.

[0042] The charging illumination coil clamping piece clamping groove 42 is arranged on the outer side wall of the second insulation end cover 44, is made of plastic, and is integrally formed with the second insulation end cover 44.

[0043] In the application, 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.

[0044] The traditional alternating current stator core, the insulating layer 4 covers the inner side wall and the outer side wall of the baffle 24, because the insulating layer 4 of the outer side wall of the baffle 24 has a certain thickness, so that 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, so that the air gap between the baffle 24 and the rotor is larger, and the magnetic flux is smaller, so that the number of turns of the enameled wire on the winding column 2 needs to be larger to meet the requirement of electromotive force, the cost of the stator core is higher, and the weight is also larger.

[0045] In the application, because the outer side wall of the baffle 24 is not provided with the insulating layer 4, 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, after the rotor and the stator are assembled, the radial air gap between the baffle 24 and the inner arc of the magnetic pole of the rotor is reduced, and therefore the magnetic flux is increased.

[0046] In addition, in the traditional alternating current stator core, the baffle 24 is covered by the insulating layer 4 and mainly guides the magnetic field through the pole shoe 23. In the application, the outer side wall of the baffle 24 is moved outward and exposed, so that 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. The baffle 24 and the pole shoe 23 guide the magnetic field at the same time, the magnetic field area is increased, and the magnetic flux is increased.

[0047] The more the number of turns of the enameled wire on the winding tooth 2, the greater the electromotive force. Under the condition that the number of turns of the enameled wire is the same, the magnetic flux of the alternating current stator core of the application is more than that of the prior art, so that the same electromotive force can be achieved with fewer turns of the enameled wire. After the number of turns of the enameled wire is reduced, the manufacturing cost of the alternating current stator core is reduced, and the weight is also reduced.

[0048] The motorcycle alternating current motor of the application, as shown in the figure, comprises a rotor 10 and a stator arranged inside the rotor 10, the stator adopts the alternating current motor stator assembly shown in the figure. Figure 9 As shown in the figure, the alternating current motor stator assembly comprises a stator main body 1 and a plurality of winding teeth 2 arranged on the outer side wall of the stator main body 1. Figures 1 to 8

[0049] The preparation method of the alternating current motor stator assembly of the application comprises the following steps:

[0050] S1, prepare the stator main body 1, the outer side wall of the stator main body 1 is provided with a plurality of winding teeth 2, adjacent two winding teeth 2 are provided with a winding slot 3, the winding tooth 2 comprises 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, and the two side edges of the pole shoe 23 are provided with arc-shaped baffles 24. This step can be realized by using the prior art.

[0051] ​S2, the insulating layer 4 is arranged on the outer side wall of the stator body 1, the outer wall of the winding tooth 2, the inner side wall of the pole shoe 23 and the inner side wall of the baffle 24, the charging ignition coil clamping piece clamping groove 42 is integrally formed with the insulating layer 4, and one end of the charging ignition coil lead-out head 41 is embedded 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 the 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 of the stator body 1, and the opening ends of the first insulating end cover 43 and the second insulating end cover 44 abut, so that the first insulating end cover 43 and the second insulating end cover 44 cover the outer side wall of the stator body 1, the outer wall of the winding tooth 2, the inner side wall of the pole shoe 23 and the inner side wall of the baffle 24.

[0053] S3, winding the charging ignition coil on the charging ignition coil winding tooth 21, and winding the charging illumination coil on the charging illumination coil winding tooth 22;

[0054] S4, tin soldering the lead-out end of the charging ignition coil to the charging ignition coil lead-out head 41, inserting the clamping piece of the charging illumination coil into the charging illumination coil clamping piece clamping groove 42, and clamping the lead-out end of the charging illumination coil to the clamping piece.

[0055] The above only describes the preferred embodiments of the present application and is not used 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 principle of the present application shall be included in the protection scope of the present application.

Claims

1. An AC motor stator assembly, comprising a stator body (1), wherein a plurality of winding teeth (2) are provided on the outer side wall of the stator body (1), and a winding groove (3) is provided between adjacent winding teeth (2); characterized in that: The winding tooth (2) includes a charging ignition coil winding tooth (21) and multiple charging lighting coil winding teeth (22); Each winding tooth (2) is provided with an arc-shaped pole shoe (23) at its top, and arc-shaped baffles (24) are provided 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). A charging ignition coil lead-out head (41) and a charging lighting coil snap-fit ​​slot (42) are fixedly provided on the insulating layer (4). After the charging lighting coil is wound, the snap-fit ​​is inserted into the charging lighting coil snap-fit ​​slot (42), and then the lead-out end of the charging lighting coil is connected to the snap-fit. The outer wall of the baffle (24) is exposed, and the outer wall of the baffle (24) and the outer wall of the pole shoe (23) are located on the same cylindrical surface.

2. The AC motor stator assembly as described in claim 1, characterized in that: The insulating layer (4) includes a first insulating end cap (43) and a second insulating end cap (44). The first insulating end cap (43) and the second insulating end cap (44) each include an integrally formed central sleeve (45), a winding tooth groove (46) disposed on the outer wall of the central sleeve (45), and a baffle cover (47) disposed on the top of the winding tooth groove (46). The stator body (1) and the winding tooth (2) are inserted into the first insulating end cap (43) and the second insulating end cap (44), and the ports of the first insulating end cap (43) and the second insulating end cap (44) abut against each other, so that the central sleeve (45) covers the outer wall of the stator body (1), the winding tooth groove (46) covers the outer wall of the winding tooth (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 as described in claim 2, characterized in that: The charging ignition coil lead-out head (41) is fixedly installed on the outer side wall of the first insulating end cover (43), and the charging lighting coil snap-fit ​​slot (42) is installed on the outer side wall of the second insulating end cover (44), and the charging lighting coil snap-fit ​​slot (42) and the second insulating end cover (44) are integrally formed.

4. The AC motor stator assembly as described in claim 2, characterized in that: The first insulating end cap (43) and the second insulating end cap (44) are plastic caps.

5. A motorcycle AC motor, comprising a rotor (10) and a stator disposed inside the rotor (10), characterized in that: The stator adopts the AC motor stator assembly as described in any one of claims 1 to 4.

6. A method for preparing the AC motor stator assembly according to any one of claims 1 to 4, characterized in that: Includes the following steps: 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). Each winding tooth (2) is provided with an arc-shaped pole shoe (23) at the top. The pole shoe (23) is provided with arc-shaped baffles (24) on both sides. 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 contact 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), while the other end is exposed. S3. Wind the charging ignition coil on the winding teeth (21) of the charging ignition coil and wind the charging lighting coil on the winding teeth (22) of the charging lighting coil. S4. Solder the lead end of the charging ignition coil to the lead end (41) of the charging ignition coil, insert the snap-fit ​​of the charging lighting coil into the snap-fit ​​slot (42) of the charging lighting coil, and snap the lead end of the charging lighting coil onto the snap-fit.

7. The method for preparing the AC motor stator assembly as described in claim 6, characterized in that: In step S2, the first insulating end cap (43) and the second insulating end cap (44) are prepared by molding process. Then, the prepared first insulating end cap (43) and the second insulating end cap (44) are respectively fitted onto the stator body (1) from both ends. The open ends of the first insulating end cap (43) and the second insulating end cap (44) abut against each other, so that the first insulating end cap (43) and the second insulating end cap (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).

Images