Method for manufacturing insulating part of block type stator unit of motor

Abstract

The invention discloses a method for manufacturing an insulating part of a motor block type stator unit, which comprises the following steps that: a coiled material is punched into insulating paper with the width B and the length A, the circumferential lengths of an inner limiting surface and an outer limiting surface of a stator core unit are C2 and C1 respectively, the tooth length, the tooth thickness and the tooth height of a winding tooth are Ta, Tb and Th respectively, B = C1 + Ta + C2, A = [1 / 2Tb + Th + (1 / 2Tb-1Tb)] * 2; the width of one long edge is B1, the length of one long edge is A3 and A3 is equal to Tb along the short symmetric axis, the width of the other long edge is B2 and the length of the other long edge is A3 along the short symmetric axis, two positions are punched from each of the left and right cut edges according to a shape of a Chinese character'zhi ', the distance B1 between each of the left and right cut edges and one long edge is equal to C1, the distance B2 between each of the left and right cut edges and the other long edge is equal to C2, and the width of each of the left and right cut edges and the other long edge is equal to Tb. The cutting length of the square shape is between 1 / 2 Tb and Tb; the T-shaped blanking part and the inverted T-shaped blanking part are bent inwards in the left-right direction; and the left and right hand edges of the insulation paper are respectively folded outwards, and the upper parts of the left and right end sides are folded inwards and connected. The insulating part is simple to manufacture and is integrally formed.

Description

Technical Field

[0001] The invention relates to the technical field of motor manufacturing, and in particular to a method for manufacturing an insulating part of a motor block-type stator unit. Background Art

[0002] In the prior art, the insulating parts used in the block-type stator unit are usually obtained by injection molding on an injection molding machine through an injection mold. Motor manufacturers need to invest in injection molding equipment. Different models of motors need to frequently design and process different molds. The injection molding process will produce emissions and therefore require investment in environmental pollution treatment funds, which ultimately leads to a high unit cost for producing insulating parts. It is well known that the production of such insulating parts also has the disadvantage of high raw material loss. Since the processing of insulating parts usually requires separate injection molding of slot insulating parts and end insulating parts, there are many injection molding steps, which will result in additional raw material loss. Summary of the invention

[0003] In view of the above-mentioned deficiencies of the prior art, the object of the present invention is to provide a method for manufacturing insulating parts of a motor block stator unit which is simple to manufacture, low in cost and high in quality. According to this method, an integrally formed insulating part can be cut and folded on a single rectangular insulating thin paper, and the entire manufacturing process is pollution-free and loss-free.

[0004] To this end, the present invention provides the following technical solutions:

[0005] A method for manufacturing an insulating member of a motor block stator unit, comprising:

[0006] Step 1, punching of the coil: punch the insulating thin paper coil of preset width into rectangular insulating thin paper, assuming: the cutting width is B, the length of the insulating thin paper is A, assuming: the circumferential length of the outer limit surface and the circumferential length of the inner limit surface of the block-type stator core unit are C1 and C2 respectively, and the tooth length, tooth thickness and tooth height of the winding teeth are Ta, Tb and Th respectively, B = the sum of C1, Ta, C2, A = 2 times the sum of 1 / 2Tb, Th, 1 / 2Tb~1Tb.

[0007] Step 2, punching the insulating thin paper: punch six places at one time on the insulating thin paper in step 1, wherein one long side is punched out along the short symmetry axis in a “⊥” shape, and the other long side is punched out along the short symmetry axis in a “⊥” shape. Punch in a “-” shape, punch two places in a “-” shape from the left and right trimming edges, and the distance from one “-” shaped punching place on the left and right trimming edges to one long side is B1 and B1=C1, and the distance from another “-” shaped punching place on the left and right trimming edges to another long side is B2 and B2=C2, and the paper feed depth at the “⊥” shaped punching place, i.e., the punching width and the punching length are B1 and A3 respectively, and A3=Tb, The blanking width and blanking length of the "-" shape blanking are B2 and A3 respectively, and the blanking length of the "-" shape blanking is between 1 / 2Tb and 1Tb.

[0008] Step 3, initial folding of the insulating thin paper: In the insulating thin paper of step 2, the punching length, Each end of the blanking length at the shape blanking part is bent inwardly with each opposite end to form a bottom surface;

[0009] Step 4, fold the insulating paper again: continue to fold the left and right sides of the insulating paper in step 3 outwards to form a left folded surface and another left folded surface facing each other, and a right folded surface and another right folded surface facing each other, and the upper parts of the left and right ends of the insulating paper are folded inwards to form left and right flanges.

[0010] Step 5, connecting the insulating thin paper: the left flange and the right flange of step 4 are fixedly connected to form a connecting surface, so as to obtain a finished insulating part which is integrally manufactured and is a single part.

[0011] Preferably, when the lengths of the left and right flanges are both greater than 1 / 2Tb and less than or equal to 1Tb, the left flange and the right flange overlap each other and are ultrasonically welded, laser welded, or adhesively bonded.

[0012] Preferably, when the lengths of the left and right flanges are both equal to 1 / 2Tb, the left and right flanges are butt-connected by a heat shrink tube.

[0013] The preparation method of the present invention has the following advantages and positive effects:

[0014] The "two punching, two folding and one connection" five-step method is adopted to form an insulating part (which is composed of a single piece of insulating thin paper) in one piece. The production is simple and the cost is low. The injection molding process that produces environmental pollution and emissions is abandoned, which is beneficial to environmental protection and energy saving. On the other hand, since this method adopts insulating thin paper rolls to form, it is more conducive to saving insulating consumables and material costs compared with conventional injection molding methods that require insulating parts with a certain thickness. In addition, there is no external or internal waste material in the entire production process, which embodies the characteristic of zero loss.

[0015] The specification design uses the ratio of three elements to form the length of the insulating paper, and the ratio of three elements to form the cutting width; the six-position design and one-time punching can ensure the positional relationship accuracy and area ratio of each insulating working surface and provide strong support for the subsequent folding forming production; the folding design not only ensures the relative position of each insulating working surface, but also facilitates the post-folding production process without being interfered by the front folding forming structure, thus having high work efficiency. In short, the production quality of this insulating part is high and is suitable for mechanized or automated production. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1Schematic diagram of insulating thin paper punched from a coil by the manufacturing method of the present invention;

[0017] Figure 2 yes Figure 1 Schematic diagram of the insulating thin paper being punched out in six places at one time;

[0018] Figure 3 A schematic diagram showing the punching and folding positions of insulating thin paper of a preset size is shown;

[0019] Figure 4 It is a schematic diagram of bending the insulating thin paper into a bottom surface according to the method of the present invention;

[0020] Figure 5 is Figure 4 Schematic diagram of the folding and turning of the insulating thin paper on the base;

[0021] Figure 6 It is a three-dimensional diagram of the insulating member of the motor block stator unit obtained by the method of the present invention;

[0022] Figure 7 It is a schematic diagram of the application of the insulating member made according to the present invention being assembled to a block-type stator core unit;

[0023] Figure 8 yes Figure 7 A three-dimensional diagram of a segmented stator core unit;

[0024] Fig. 9 It is an end view of the segmented stator core unit;

[0025] Fig.10 It is a simplified diagram of the production process of the present invention. DETAILED DESCRIPTION

[0026] See also Figures 1 to 10 As shown, a method for manufacturing an insulating member of a motor block stator unit comprises:

[0027] S1, punching and cutting the coil into insulating thin paper: The 0.25 mm thick insulating thin paper coil with a preset width is unwound on a punching machine and punched into rectangular insulating thin paper 1 (such as Figure 1 ), see Figure 3 As shown, assume that the trimming width is B, the length of the insulating paper is A, assume that the circumferential length of the outer limiting surface 710 and the circumferential length of the inner limiting surface 720 of the block-type stator core unit 7 are C1 and C2 respectively, and the tooth length, tooth thickness and tooth height of the winding tooth 70 of the block-type stator core unit 7 are Ta, Tb and Th respectively, B = C1 + Ta + C2, A = [1 / 2Tb + Th + (1 / 2Tb ~ 1Tb)] × 2, combined Figure 8 , 9 shown.

[0028] For the convenience of description, the axial direction of the block-type stator core unit 7 in this embodiment is as follows: Figure 8 As shown in the H direction, the radial and circumferential directions are as follows Fig. 9 The tooth length, tooth thickness and tooth height refer to the radial length, tooth wall thickness and axial height of the winding tooth respectively.

[0029] S2, Insulation paper punching: see Figure 2 , continue to use the punching machine to punch six places on the insulating thin paper in step S1 at the same time, wherein, from one long side 1U, one place is punched out along the short symmetry axis in a "⊥" shape, and from the other long side 1D, one place is punched out along the short symmetry axis in a "⊥" shape. One is punched out in a "-" shape, two are punched out in a "-" shape from the left cut edge 1L, and two are punched out in a "-" shape from the right cut edge 1R, and the intervals from a "-" shaped punching point 1L-1 from the left cut edge and a "-" shaped punching point 1R-1 from the right cut edge to a long side 1U are both B1, and B1=C1, and the intervals from another "-" shaped punching point 1L-2 from the left cut edge and another "-" shaped punching point 1R-2 from the right cut edge to another long side 1D are both B2, and B2=C2, combined with Figure 3 .

[0030] The short symmetry axis refers to a straight line passing through the intersection of the diagonals of the rectangular insulating paper and parallel to the left and right cut edges.

[0031] The paper feed depth of the “⊥”-shaped punching position 1U', i.e., the punching width and the punching length (across the short symmetry axis and symmetrically located on both sides thereof) are B1 and A3 respectively, A3 = Tb, The paper feed depth of the "-" shaped punching position 1D', i.e., the punching width and the punching length (similarly across the short symmetry axis and symmetrically located on both sides thereof) are B2 and A3 respectively, and the punching length of the "-" shaped punching is between 1 / 2Tb and 1Tb. In detail, the punching lengths of one "-" shaped punching position 1L-1 and another "-" shaped punching position 1L-2 are both A1, A1 = 1 / 2Tb ~ 1Tb, and the punching lengths of one "-" shaped punching position 1R-1 and another "-" shaped punching position 1R-2 are both A2, A2 = 1 / 2Tb ~ 1Tb.

[0032] The punching width mentioned here refers to the cutting width direction of the insulating thin paper, and the punching length refers to the long side direction of the insulating thin paper; a "- " shaped punching position 1L-1, a "- " shaped punching position 1R-1, another "- " shaped punching position 1L-2, and another "- " shaped punching position 1R-2 are respectively parallel to the long symmetry axis or parallel to the long side of the insulating thin paper.

[0033] S3, the insulating thin paper is initially folded into the bottom surface: the folding machine is based on Figure 3The punching position shown and the dotted line position near the center are implemented to form the bottom surface 2D based on In detail, fold the “⊥” shaped blanking portion inwards towards the “⊥” shaped blanking portion. The blanking length of the blanking part 1D' is connected along one end (left end in the figure) Figure 3 The dotted line 2D-1 near the center left is bent inward, and the other end of the blanking length (the right end in the figure) of the "⊥"-shaped blanking portion IU' is formed. The other end of the blanking length (the right end in the figure) is along the Figure 3 The dotted line 2D-2 near the center right is bent inward, and the two folds formed by the bending of the two dotted lines are respectively connected to the "⊥"-shaped punching part and The shaped blanking intersection forms a layer at the bottom of the insulating thin paper. Figure 4 In the bottom surface 2D shown, two folds constitute a set of two opposite sides of the bottom surface, and the distance between the two folds is A3, A3 = Tb.

[0034] S4, the insulating thin paper is folded into the insulating part blank: continue to fold the edge of the machine according to the Figure 3 The punching position shown and the dotted line (not shown) position near the cutting edge are implemented to form a left folding surface 3L-1 and another left folding surface 3L-2, based on the "⊥"-shaped punching position 1U' associated with a "-"-shaped punching position 1L-1 and The “⊥” shaped punching 1U′ is associated with another “-” shaped punching 1L-2, which is folded outwards respectively, and in order to form a right folding surface 4R-1 and another right folding surface 4R-2, a “-” shaped punching 1R-1 and a “⊥” shaped punching 1U′ are associated with each other. A "- " shaped punching point 1D' is associated with another "- " shaped punching point 1R-2 and are folded outward respectively; and in order to form a left flange 5L and a right flange 5R, a "- " shaped punching point 1L-1 is associated with another "- " shaped punching point 1L-2 and are folded inward together to form a left flange 5L, and a "- " shaped punching point 1R-1 is associated with another "- " shaped punching point 1R-2 and are folded inward together to form a right flange 5R.

[0035] The left hand side of the insulating thin paper 1 in step S3 is folded outward (relative to the inward side of S3) to form a left folded surface 3L-1 and another left folded surface 3L-2 facing each other, and the right hand side of the insulating thin paper 1 is also folded outward to form a right folded surface 4R-1 and another right folded surface 4R-2 facing each other, and the upper parts of the left and right ends of the insulating thin paper are folded along the Figure 3The two dotted lines near the cutting edge are folded inward to form a left flange 5L and a right flange 5R, wherein a left folded surface 3L-1 and another left folded surface 3L-2 respectively intersect with the left flange 5L and the bottom surface 2D to form a left side surface 6L, and a right folded surface 4R-1 and another right folded surface 4R-2 respectively intersect with the right flange 5R and the bottom surface 2D to form a right side surface 6R.

[0036] S5, insulation paper connection as finished product: see Figure 6 As shown, the left flange 5L and the right flange 5R of step S4 are fixedly connected to form a connecting surface 5, the length of which is Tb, to obtain an insulating component finished product that is integrally manufactured and is a single part.

[0037] Continue to see Figure 6 As a preferred implementation, when the length A1 of the left flange and the length A2 of the right flange are both greater than 1 / 2Tb and less than or equal to 1Tb, the left flange and the right flange overlap each other and are ultrasonically welded, laser welded or adhesively bonded.

[0038] When the length A1 of the left flange and the length A2 of the right flange are both equal to 1 / 2Tb, the left and right flanges are butt-connected by a heat shrink tube (not shown).

[0039] When the insulating part made by the present method is assembled on the block-type stator core unit 7, the bottom surface 2D is attached to a tooth end surface 701 of the winding tooth 70, the left side surface 6L and the right side surface 6R are respectively attached to the opposite tooth vertical surfaces 702 of the winding tooth 70, a left fold surface 3L-1 and a right fold surface 4R-1 are respectively attached to the corresponding two circumferentially spaced outer limit surfaces 710 and extend beyond the two outer limit surfaces of the yoke 71, and another left fold surface 3L-2 and another right fold surface 4R-2 are respectively attached to the corresponding two spaced inner limit surfaces 720 and extend beyond the two inner limit surfaces of the pole shoe 72, finally, the left flange 5L and the right flange 5R are overlapped and fixed, and then attached to cover the other tooth end surface of the winding tooth (not visible and not marked in the figure).

[0040] The manufacturing process of the present invention is excellently designed: punching out insulating thin paper from insulating thin paper coil → punching at six positions at a time → bending to form the bottom surface → folding the long sides to form the folded surface and folding the flanges and naturally forming the two side surfaces, which is conducive to realizing mechanical automatic punching operations and mechanical automatic folding operations.

Claims

1. A method for manufacturing an insulating member of a motor block stator unit, characterized in that: include: Step 1, punching of coiled material: punching an insulating thin paper coiled material of a preset width into rectangular insulating thin paper, assuming that the cutting width is B, the length of the insulating thin paper is A, assuming that the circumferential length of the outer limit surface and the circumferential length of the inner limit surface of the block-type stator core unit are C1 and C2 respectively, and the tooth length, tooth thickness and tooth height of the winding teeth are Ta, Tb and Th respectively, B = the sum of C1, Ta and C2, A = 2 times the sum of 1 / 2Tb, Th and 1 / 2Tb to 1Tb; Step 2, punching of insulating thin paper: punching six places at one time on the insulating thin paper in step 1, wherein one long side is punched out along the short symmetry axis in a "⊥" shape, the other long side is punched out along the short symmetry axis in a "T" shape, two places are punched out from the left trimming edge and the right trimming edge in a "-" shape, and the interval distance from one "-" shaped punching place of each of the left and right trimming edges to one long side is B1 and B1=C1, and the interval distance from another "-" shaped punching place of each of the left and right trimming edges to another long side is B2 and B2=C2, the paper feed depth of the "⊥" shaped punching place, i.e., the punching width and the punching length are B1 and A3 respectively, A3=Tb, the punching width and the punching length of the "T" shaped punching place are B2 and A3 respectively, and the punching length of the "-" shaped punching is between 1 / 2Tb and 1Tb; Step 3, initial folding of the insulating thin paper: in the insulating thin paper of step 2, one end of the punching length at the "⊥"-shaped punching position and the punching length at the "T"-shaped punching position are bent inward with each opposite end to form a bottom surface; Step 4, folding the insulating thin paper again: continue to fold the left and right sides of the insulating thin paper in step 3 outwards to form a left folded surface and another left folded surface facing each other, and a right folded surface and another right folded surface facing each other, and the upper parts of the left and right ends of the insulating thin paper are folded inwards to form a left turn-over and a right turn-over; Step 5, connecting the insulating thin paper: the left flange and the right flange of step 4 are fixedly connected to form a connecting surface, so as to obtain a finished insulating part which is integrally manufactured and is a single part.

2. The method for manufacturing an insulating member for a motor block stator unit according to claim 1, characterized in that: When the lengths of the left and right flanges are both greater than 1 / 2Tb and less than or equal to 1Tb, the left flange and the right flange overlap each other and are ultrasonically welded, laser welded or adhesively bonded.

3. The method for manufacturing an insulating member for a motor block stator unit according to claim 1, characterized in that: When the lengths of the left and right flanges are both equal to 1 / 2Tb, the left and right flanges are butt-connected through a heat shrink tube.

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