Motor stator core winding notch structure and chamfer insulation processing method thereof

Abstract

The invention relates to a motor stator core winding notch structure and a chamfer insulation processing method thereof, the structure comprises a stator core winding notch, the stator core winding notch is provided with a chamfer structure at two end positions or one end position of the stator core winding notch in the height direction of an iron core to form an oblique angle or a circular bead or a natural melting collapse surface with a set size, and the chamfer structure is provided with a chamfer groove. The stator core winding notch is partially or completely provided with an insulation protection layer. Compared with the prior art, the winding structure has the advantages that the winding can be directly performed on the stator core under the condition of not adding extra parts such as an insulating framework, the cost is reduced, the winding slot fullness rate and the motor performance are improved, and the like.

Description

Technical Field

[0001] The invention relates to a motor stator core, in particular to a motor stator core winding notch structure and a chamfer insulation processing method thereof. Background Art

[0002] The existing technology generally includes the following methods for processing the stator core winding slots:

[0003] 1. Injection molding frame: Place the iron core into the injection mold, and form an injection molding layer of a certain thickness on the surface in contact with the winding coil, thereby separating the iron core from the enameled wire. The thickness of the injection molding layer is usually at least 0.2mm. This method has high mold cost, long manufacturing cycle and high cost.

[0004] 2. Insulating paper: Insert insulating paper of a certain thickness into the winding slot to separate the winding coil from the stator core. This method will cause the coil end to be higher and is not suitable for split-type combined core applications.

[0005] 3. Direct insulation coating: Spray or dip the insulation material on the surface of the core in contact with the winding coil. Even so, due to the limitations of the stator core punching process, the winding notches on the upper and lower surfaces of the stator core are close to sharp corners, which makes it difficult for the insulation layer to adhere stably. During winding, the winding tension causes partial insulation damage and failure, and even cuts the insulation protection layer of the wire itself.

[0006] To avoid this situation, the existing approach is to add an insulating frame at the winding slot positions at both ends of the stator. This not only increases the cost, but also occupies the winding space, reduces the slot fill rate, and reduces the motor performance.

[0007] Therefore, for motor stators with high power density requirements, how to ensure insulation performance, not occupy additional winding space, while increasing the winding slot fill rate, reducing power consumption, and improving motor performance is a technical problem that needs to be solved. Summary of the invention

[0008] The purpose of the present invention is to overcome the defects of the above-mentioned prior art and provide a motor stator core winding slot structure and a chamfer insulation processing method thereof.

[0009] The purpose of the present invention can be achieved by the following technical solutions:

[0010] According to one aspect of the present invention, a motor stator core winding slot structure is provided, which includes a stator core winding slot, and the stator core winding slot is provided with a chamfer structure at both end positions in the core height direction or at the end position on one side to form a set size of bevel or rounded corner or a naturally melted collapsed surface, and the stator core winding slot is partially or completely provided with an insulating protective layer.

[0011] As a preferred technical solution, the bevel angle is greater than 15° and less than 80°.

[0012] As a preferred technical solution, the fillet radius R is greater than or equal to 0.05 mm.

[0013] As a preferred technical solution, the fillet intersects or is tangent to the stator core winding slot.

[0014] As a preferred technical solution, the arc length of the bevel or rounded corner is not less than 0.05 mm.

[0015] As a preferred technical solution, the bevel or rounded corner is formed by laser melting or removing metal material.

[0016] As a preferred technical solution, the insulating protective layer is an insulating protective layer formed by electrophoretic coating, insulating material spraying, insulating material dipping or insulating coating.

[0017] According to another aspect of the present invention, a chamfering and insulation treatment method for the stator core winding slot structure of the motor is provided, wherein the method uses laser melting or material removal to chamfer the stator core winding slot, and performs insulation treatment on part or all of the stator core winding slot.

[0018] As a preferred technical solution, the chamfering process is specifically: using a laser to melt or remove material from the acute angles of the ends of the stator core winding slots on both sides in the core height direction or on one side to form a set size of bevel or rounded corner or a naturally melted collapsed surface.

[0019] As a preferred technical solution, the insulation treatment is specifically a process of forming an insulating protective layer partially or completely on the winding slots of the stator core by electrophoretic coating, insulating material spraying, insulating material dipping or insulating coating.

[0020] Compared with the prior art, the present invention has the following advantages:

[0021] 1) The insulated structure of the winding slot chamfer of the motor stator core of the present invention and its processing technology can directly wind on the stator core without adding additional components such as an insulating frame, thereby reducing costs and improving the winding slot full rate and motor performance;

[0022] 2) The present invention performs chamfering process on the two end positions or one end position of the winding slot of the stator core punching sheet in the core height direction to form a certain size of bevel or rounded corner, thereby improving the reliability of the surface insulation treatment of the stator core winding slot in the later stage;

[0023] 3) The present invention implements partial or complete insulation treatment on the stator winding slot position, which can save additional components such as insulation frame, insulation paper, etc., while ensuring good insulation performance, increasing the effective winding space, improving the winding slot full rate, reducing costs and improving the performance of the motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a structural schematic diagram of the chamfering of winding slots of a split-type stator core according to an embodiment of the present invention;

[0025] Figure 2 This is a schematic structural diagram of the chamfering of winding slots of an integral stator core according to an embodiment of the present invention;

[0026] FIG3( a ) is a schematic diagram showing a structural comparison of a split-type stator core before the winding slots are chamfered according to an embodiment of the present invention;

[0027] FIG3( b ) is a schematic diagram of the enlarged structure of part B of FIG3( a );

[0028] FIG4( a ) is a schematic diagram showing a structure comparison of the stator core winding slots after chamfering in a split-type stator core according to an embodiment of the present invention;

[0029] FIG4( b ) is a schematic diagram of the enlarged structure of part A of FIG4( a );

[0030] 1 is the upper end punching sheet, 2 is the lower end punching sheet, 11 is the stator yoke, 12 is the stator tooth, 3 is the stator core winding slot, 4 is the chamfering structure, and 5 is the winding slot before chamfering. DETAILED DESCRIPTION

[0031] 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 part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of the present invention.

[0032] Example

[0033] like Figure 1 and Figure 2 As shown, a motor stator core winding slot structure includes a stator core winding slot 3, and the stator core winding slot 3 is provided with a chamfer structure 4 at both end positions in the core height direction or at the end position on one side to form a set size of bevel or fillet or a naturally melted collapsed surface, and the stator core winding slot is partially or completely provided with an insulating protective layer.

[0034] The stator core is a split-type or integral core assembly formed by punching and laminating the core material and adopting various fixing methods such as riveting, bonding, welding and the like.

[0035] The stator core winding slot refers to a winding area formed between the stator yoke and the stator teeth on the motor stator core body, and is used for winding coils on the stator core.

[0036] The arc size of the bevel or rounded corner is not less than 0.05 mm, which increases the natural bending radius of the winding and provides process guarantee for stable and reliable attachment of subsequent surface insulation treatment.

[0037] The bevel angle is greater than 15° and less than 80°, the fillet radius R is greater than or equal to 0.05 mm, the fillet can intersect or be tangent to the stator core winding slot, and the bevel or fillet is formed by laser melting or removing metal material, so it is an approximate bevel or fillet. The present invention achieves the removal of the root contact sharp angle of the stator core winding slot during winding. The use of laser chamfering can avoid the traditional metal cutting method applying additional force to the core, causing excessive deformation of the core surface or the stator core causing fragmentation due to external force.

[0038] On this basis, insulation treatment is performed partially or completely on the winding slots of the stator core. Due to the chamfer, the damage to the insulation layer caused by the contact sharp corners can be avoided, the adhesion of the insulation layer can be improved, and the risk of insulation failure at the sharp corners of the winding slots due to the winding tension during winding can be avoided, and the risk of puncturing the insulation layer of the winding wire can be avoided. The insulation treatment refers to the process of forming an insulating protective layer partially or completely on the winding slots of the stator core by electrophoretic coating, insulating material spraying, insulating material dipping or insulating coating.

[0039] Example 2

[0040] As attached Figure 1 , Figure 2 As shown, the stator core winding slots are chamfered by laser melting or material removal. Figure 3(a) and 3(b) This is the shape of the winding notch before chamfering. Figure 4(a) and 4(b) It is a partial enlarged diagram of the winding groove after chamfering.

[0041] The stator core winding slots are chamfered by laser melting or material removal.

[0042] Due to the characteristics of laser energy concentration, wide range of adaptability to processing materials, small processing stress and small deformation, the desired ideal shape can be obtained more conveniently.

[0043] Laser is used to melt or remove materials at the contour position where the winding slot contacts the winding wire on one or both sides of the stator core height direction, and the sharp angles at the ends of both sides or one side of the stator core winding slot in the core height direction are removed to form a certain size of bevel or fillet or a naturally melted collapsed surface. This process method removes the sharp contact angle of the root of the stator core winding slot during winding.

[0044] On this basis, insulation treatment is performed partially or completely on the stator core winding slots. The insulation treatment refers to a process of forming an insulating protective layer partially or completely on the stator core winding slots by electrophoretic coating, insulating material spraying, insulating material dipping, or insulating coating.

[0045] The chamfer can avoid damage to the insulation layer by the contact sharp corners, improve the adhesion of the insulation layer, and avoid the risk of insulation failure at the sharp corners of the winding groove due to the winding tension during winding, and puncturing the insulation layer of the wound wire.

[0046] The above is only a specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can easily think of various equivalent modifications or replacements within the technical scope disclosed by the present invention, and these modifications or replacements should be included in the protection scope of the present invention. Therefore, the protection scope of the present invention shall be based on the protection scope of the claims.

Claims

1. A motor stator core winding slot structure, characterized in that: The structure comprises a stator core winding slot, which is provided with a chamfered structure at both end positions in the core height direction or at one end position of one side to form an inclined angle or a rounded angle or a naturally melted collapsed surface of a set size, and part or all of the stator core winding slot has an insulating protective layer.

2. The motor stator core winding slot structure according to claim 1, characterized in that: The bevel angle is greater than 15° and less than 80°.

3. The motor stator core winding slot structure according to claim 1, characterized in that: The fillet radius R is greater than or equal to 0.05 mm.

4. The motor stator core winding slot structure according to claim 1, characterized in that: The fillet intersects or is tangent to the stator core winding slot.

5. The motor stator core winding slot structure according to claim 1, characterized in that: The arc length of the bevel or rounded corner is not less than 0.05 mm.

6. The motor stator core winding slot structure according to claim 1, characterized in that: The bevel or rounded corner is formed by laser melting or removing metal material.

7. The motor stator core winding slot structure according to claim 1, characterized in that: The insulating protective layer is formed by electrophoretic coating, insulating material spraying, insulating material dipping or insulating coating.

8. A chamfer insulation treatment method for the stator core winding slot structure of the motor according to claim 1, characterized in that: The method uses laser melting or material removal to chamfer the stator core winding slots, and performs insulation treatment on part or all of the stator core winding slots.

9. The chamfer insulation processing method according to claim 8, characterized in that: The chamfering process is specifically as follows: using laser to melt or remove material from the acute angles of both ends or one end of the stator core winding slot in the core height direction to form a bevel or rounded corner of a set size or a naturally melted collapsed surface.

10. The chamfer insulation processing method according to claim 8, characterized in that: The insulation treatment is specifically a process of forming an insulation protection layer partially or completely on the winding slots of the stator core by means of electrophoretic coating, insulation material spraying, insulation material dipping or insulation coating.

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