Stator core assembly, motor and winding method

Abstract

The invention relates to a stator core assembly, a motor and a winding method, the stator core assembly comprises a plurality of independent basic units, each basic unit comprises a plurality of independent basic components, each basic component is provided with a tooth part and a circumferential part, the tooth part extends along the radial direction, the circumferential part extends along the circumferential direction, and the tooth part extends along the radial direction. The multiple independent basic components of each basic unit are sequentially stacked in the axial direction, so that the tooth parts of all the basic components of each basic unit jointly form the tooth part of the basic unit, and the circumferential parts of all the basic components of each basic unit jointly form the circumferential part of the basic unit; and each basic component of each basic unit is sequentially connected with the corresponding basic component of the adjacent basic unit, so that the stator core assembly in a closed ring shape is formed. According to the invention, the stator core assembly is arranged to be formed by connecting the plurality of independent basic units, so that a larger winding space is provided during winding, and the plurality of basic units can be wound at the same time.

Description

Technical Field

[0001] The present invention relates to the technical field of motors, and in particular to a stator core assembly, a motor having the stator core assembly, and a winding method. Background Art

[0002] The motor has a stator assembly and a rotor assembly. Generally speaking, the stator assembly includes a stator core assembly, on which windings are wound. In a common stator core assembly, the stator core is formed by stacking a plurality of silicon steel sheets, and then windings are wound on the stator teeth. Since the silicon steel sheet itself is a closed ring and the stator teeth protrude radially inward, only the inner winding method can be used when winding the windings. Considering the size of the stator, this limits the slot fill rate. At the same time, in order to facilitate winding, one way is to increase the slot space, but a larger slot will bring greater torque fluctuations.

[0003] In addition, in common motors, multiple stator teeth that are located at the same position in the circumferential direction and stacked on each other in the stator core completely overlap in the axial direction. The tooth slots formed in this way are called straight slots. This straight slot form of tooth slots makes the motor have a higher tooth slot torque. Summary of the invention

[0004] In order to solve one or more of the above technical problems at least to a certain extent, the present invention proposes the following technical solutions.

[0005] A stator core assembly, comprising:

[0006] A plurality of separate basic units, each of which comprises a plurality of separate basic components, each of which comprises a tooth portion and a circumferential portion, wherein the tooth portion extends in a radial direction, and the circumferential portion extends in a circumferential direction, and the plurality of separate basic components of each basic unit are sequentially stacked in an axial direction, so that the tooth portions of all the basic components of each basic unit together form the tooth portion of the basic unit, and the circumferential portions of all the basic components of each basic unit together form the circumferential portion of the basic unit;

[0007] Each basic component of each basic unit is connected in sequence with the corresponding basic component of the adjacent basic unit, so as to form the stator core assembly in a closed ring shape.

[0008] According to the above scheme, the present invention arranges the stator core assembly to be connected by multiple individual basic units to form a complete stator core assembly, so that when winding, all the basic units constituting the stator core assembly can be arranged in a straight line, thereby having a larger winding space, and being able to wind multiple basic units at the same time. Correspondingly, the slot fill rate of the stator formed thereby is also higher. In addition, the basic units are separate structures from each other, and each basic unit is composed of multiple separate basic components, making the manufacture, storage, and transportation of the basic components easier, and the required volume is also smaller.

[0009] According to an example of the present invention, a recess is provided on the circumferentially extending contour of the radially proximal end of the tooth portion of the basic component.

[0010] According to an example of the present invention, the recess is in an arc shape and is located in the middle of the circumferentially extending profile. By providing such a recess on the tooth portion, high-order harmonics can be reduced, thereby improving the NVH performance of the motor when it is running.

[0011] According to an example of the present invention, the tooth portion of the basic unit has two radial side surfaces, and when viewed along the axial direction, only one of the two radial side surfaces can be observed.

[0012] Through this arrangement, the tooth groove formed between the tooth parts of two adjacent basic units no longer extends in a direction parallel to the axial direction, but is formed into an inclined tooth groove. With this form of tooth groove, the tooth groove torque can be greatly reduced.

[0013] According to an example of the present invention, when viewed along the axial direction, each basic component forming a basic unit does not completely overlap.

[0014] According to an example of the present invention, a circumferential portion of the basic component is provided with a mounting portion for connecting with a tool.

[0015] According to an example of the present invention, the circumferential portion of the basic component has two positioning portions, and each basic component is connected to two adjacent basic components via the two positioning portions.

[0016] According to an example of the present invention, the two positioning portions are complementary in shape.

[0017] By providing complementary positioning portions, adjacent basic components or basic units can be easily connected to each other and can be aligned, so that multiple basic components or basic units are connected to form a stator core assembly.

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

[0019] In addition, the present invention also provides a winding method, comprising the following steps:

[0020] a) preparing a plurality of the above basic units;

[0021] b) Arrange all basic units in a non-closed form and fix them to the tooling;

[0022] c) winding wire around the teeth of the basic unit;

[0023] d) Wind all the basic units to form a stator core assembly.

[0024] Other features and advantages of the present invention will be described in detail below in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Exemplary embodiments of the present invention are described with reference to the accompanying drawings, in which:

[0026] Figure 1 A perspective view of a stator core assembly of the present invention is shown.

[0027] Figure 2 A three-dimensional view of a basic unit of a stator core assembly of the present invention is shown.

[0028] Figure 3 A front view of the basic components is shown.

[0029] Figure 4 A perspective view of the basic components is shown.

[0030] Figure 5 The schematic diagram of the arrangement of the basic units during stator winding of the present invention is shown.

[0031] Figure 6 A top view of the stator core assembly of the present invention is shown.

[0032] All the drawings are only schematic and not necessarily drawn to scale, and they only show those parts necessary for explaining the present invention, and other parts are omitted or only mentioned. That is, in addition to the parts shown in the drawings, the present invention may also include other parts.

[0033] In the figures, identical and / or functionally identical technical features are provided with identical or similar reference numerals. DETAILED DESCRIPTION

[0034] Embodiments of the present invention are described below with reference to the accompanying drawings. In the following description, many specific details are set forth so that those skilled in the art can more fully understand and implement the present invention. However, it will be apparent to those skilled in the art that the present invention may be implemented without some of these specific details. In addition, it should be understood that the present invention is not limited to the specific embodiments described. On the contrary, any combination of the features and elements described below may be considered to implement the present invention, regardless of whether they relate to different embodiments. Therefore, the following aspects, features, embodiments and advantages are intended for illustration purposes only and should not be considered as features or limitations of the claims unless explicitly stated in the claims.

[0035] In the following description, the descriptions about directions, such as "upper", "lower", "inner", "outer", "radial", "axial", etc., which may be used, are only for the convenience of description, unless otherwise specified, and are not intended to form any limitation on the technical solution of the invention. In addition, in the following description, terms such as "first", "second", etc. are used to describe the elements of the present application, and these terms are only used to distinguish the elements, and are not intended to limit the nature, sequence, order or number of these elements.

[0036] Figure 1 FIG. 2 shows a three-dimensional view of the stator core assembly of the present invention. Figure 1 As can be seen in the figure, the stator core assembly 1000 of the present invention is composed of a plurality of basic units 100, and the plurality of basic units 100 are connected to each other in the circumferential direction to form a complete stator core assembly 1000. A cavity 1001 is provided radially inside the stator core assembly 1000. The stator core assembly has a circular outer contour and accordingly has an axis or defines an axis.

[0037] The stator core assembly in the prior art is formed by stacking a plurality of basic units in the axial direction, each of which has a ring-shaped body, and a plurality of stator teeth extend radially inward from the ring-shaped body. Similarly, in the stator core assembly in the prior art, there is also a cavity radially inside. As has been pointed out in the background art, since only inner winding can be used when winding the stator teeth, the winding is limited by the size of the cavity.

[0038] In order to overcome the above-mentioned shortcomings in the prior art, the present invention proposes basic units in different forms. Figure 2 A three-dimensional diagram of a basic unit of the stator core assembly of the present invention is shown. Figure 2 It can be seen from the figure that each basic unit 100 is formed by stacking a plurality of basic components 10 in the axial direction. Figure 5 The schematic diagram of the arrangement of the basic units of the stator winding of the present invention is shown. Figure 5It can be seen from the figure that during winding, a plurality of basic units 100 are arranged along a straight line on the tooling 200, and then the wires are wound around the stator teeth. Figure 5 It can be seen that, since the multiple basic units 100 are arranged in a straight line during winding, there is more space available for winding, unlike the circular stator core in the prior art, which can only be wound inside the circumference. In addition, since there is more space, it is also possible to wind on multiple stator teeth at the same time, thereby improving the winding efficiency. After the winding is completed, the coiling process can be used to Figure 5 The plurality of basic units 100 shown form Figure 1 The closed annular structure shown forms a stator core assembly. Accordingly, according to the same winding process, more wires can be wound in the stator slots of the same size, so that the slot fill rate of the stator can be higher.

[0039] Of course, those skilled in the art know that the multiple basic units 100 do not have to be arranged in a straight line, but can also be arranged in a certain arc, or in other non-closed arrangements. As long as the multiple basic units do not form a closed form, it can have a better Figure 1 The cavity 1001 shown provides more room for winding wires.

[0040] On the basis of the above basic concept, the present invention also proposes improvements in other aspects, which will be described below.

[0041] Figure 3 A front view of the basic components is shown. Figure 4 A three-dimensional diagram of the basic components is shown. Figure 3 and Figure 4 It can be seen that the basic component 10 has a body, which includes a tooth portion 11. In the stator core assembly, the tooth portion 11 extends radially. The tooth portion 11 has two radially extending profiles that are preferably parallel to each other, and a circumferentially extending profile located at the radial proximal end. Here, the radial proximal end refers to an end close to the axis of the stator core assembly. Correspondingly, the radial distal end refers to an end away from the axis of the stator core assembly, that is, an end opposite to the radial proximal end.

[0042] A circumferential portion 12 having two arm portions is formed by extending from the radial distal end of the tooth portion 11 to both sides in the circumferential direction. The circumferential portion 12 has a circumferential outer contour and a circumferential inner contour, and the tooth portion 11 is connected to the circumferential inner contour.

[0043] On the circumferential portion 12, in order to connect the basic component 10 with the tooling 200, a mounting portion 13 is provided. Preferably, a radially inward recess is provided on the circumferential outer contour of the circumferential portion 12, thereby forming the mounting portion 13. It is also conceivable that a radially outward protrusion is provided on the circumferential outer contour of the circumferential portion 12, thereby forming the mounting portion 13. Accordingly, a structure complementary to the shape of the mounting portion 13 may be provided on the tooling 200. The mounting portion 13 is preferably provided in the middle of the circumferential outer contour.

[0044] from Figure 3 and Figure 4 It can also be seen that the circumferential portion 12 has two radial profiles in the radial direction, and a positioning portion 14 is formed on the radial profile. Specifically, on one of the radial profiles, the positioning portion 14 is in the form of a projection, and on the other radial profile, the positioning portion 14 is in the form of a depression. Thus, when a plurality of basic components 10 are connected in sequence to form a complete closed structure in the circumferential direction, the two positioning portions 14 on each basic component 10 are respectively connected to the corresponding positioning portions 14 on two adjacent basic components 10, thereby fixing the plurality of basic components 10. Preferably, the outer profile of the positioning portion 14 has two arc portions around the axis, so that the positioning portion 14 has a centering function.

[0045] As an important improvement of the present invention, a recess 15 is provided on the tooth portion 11 of the basic component 10 on the circumferentially extending profile at the radial proximal end. Preferably, the recess 15 is in an arc shape. Preferably, the recess 15 is located in the middle of the circumferentially extending profile. By providing such a recess on the tooth portion 11, high-order harmonics can be reduced, thereby improving the NVH performance of the motor when it is running.

[0046] As another important improvement of the present invention, Figure 1 , Figure 2 as well as Figure 6 It can be seen that in the stator core assembly of the present invention, the tooth portion of each basic unit 100 has two radial side surfaces on both sides thereof, and only one of the two radial side surfaces can be observed when viewed along the axial direction. In other words, the radial side surface that can be observed is inclined or at an angle relative to a plane parallel to the axis and passing through a radially extending edge of a tooth portion of any basic component of the basic unit. Figure 6 This is particularly evident in Figure 6 In the figure, when viewed along the direction perpendicular to the paper surface, that is, the axial direction, it can be seen that the black part corresponds to a radial side surface of the tooth portion of the basic unit 100. Preferably, the two radial side surfaces of the tooth portion of the basic unit 100 are parallel to each other.

[0047] Through this arrangement, the space formed between the teeth of two adjacent basic units 100, also called tooth grooves, is no longer a straight groove in which each surface extends in a direction parallel to the axial direction, but is formed into inclined tooth grooves. This form of tooth groove can greatly reduce the tooth groove torque.

[0048] from Figure 1 and Figure 2 It can be clearly seen that when a single basic component 10 is used to form Figure 6 When the stator core assembly is shown, it can be realized by making each basic component 10 of each basic unit 100 have a certain offset with the adjacent basic components 10 in sequence when stacked. Figure 1 This offset can be seen from the fact that the mounting portions of each basic component 10 of each basic unit 100 jointly form a groove extending obliquely. In other words, when viewed along the axial direction, each basic component forming a basic unit does not completely overlap.

[0049] like Figure 4 As shown, the surface of the basic component 10 perpendicular to the axis is called the first plane P1, and the side surface of the tooth portion of the basic component for defining the thickness of the basic component is called the second plane P2. Preferably, in order to make the radial side surface of the tooth portion of each basic unit 100 a flat plane, the second plane P2 of each basic component 10 is not perpendicular to the first plane P1 during manufacturing, but has a certain inclination.

[0050] The structure and preparation of the stator core assembly of the present invention and the method of winding wires thereon are described in detail above.

[0051] The present invention has been clearly and completely described with reference to the above exemplary embodiments, and it should be understood by those skilled in the art that various other embodiments can be conceived by modifying the disclosed technical solutions without departing from the spirit and scope of the present invention. These embodiments should be understood to fall within the scope of the present invention determined based on the claims and any equivalent technical solutions thereof.

Claims

1. A stator core assembly, characterized in that: The stator core assembly comprises: A plurality of separate basic units, each of which comprises a plurality of separate basic components, each of which comprises a tooth portion and a circumferential portion, wherein the tooth portion extends in a radial direction, and the circumferential portion extends in a circumferential direction, and the plurality of separate basic components of each basic unit are sequentially stacked in an axial direction, so that the tooth portions of all the basic components of each basic unit together form the tooth portion of the basic unit, and the circumferential portions of all the basic components of each basic unit together form the circumferential portion of the basic unit; Each basic component of each basic unit is connected in sequence with the corresponding basic component of the adjacent basic unit, so as to form the stator core assembly in a closed ring shape.

2. The stator core assembly according to claim 1, characterized in that: A recess is arranged on a circumferentially extending contour of a radially proximal end of the toothed portion of the basic component.

3. The stator core assembly according to claim 2, characterized in that: The recess is in an arc shape and is located in the middle of the circumferentially extending contour.

4. The stator core assembly according to any one of claims 1 to 3, characterized in that: The tooth portion of the basic unit has two radial side surfaces, and only one of the two radial side surfaces can be observed when viewed in the axial direction.

5. The stator core assembly according to any one of claims 1 to 3, characterized in that: When viewed along the axial direction, each basic component forming a basic unit does not completely overlap.

6. The stator core assembly according to any one of claims 1 to 3, characterized in that: The circumferential portion of the basic component is provided with a mounting portion for connecting with a tool.

7. The stator core assembly according to any one of claims 1 to 3, characterized in that: The circumferential portion of the basic component has two positioning portions, and each basic component is connected to two adjacent basic components via the two positioning portions.

8. The stator core assembly according to claim 7, characterized in that: The two positioning portions are complementary in shape.

9. A motor, characterized in that: The invention comprises a stator core assembly as claimed in any one of claims 1 to 8.

10. A winding method, characterized in that: The steps include: a) preparing a plurality of basic units according to any one of claims 1 to 8; b) Arrange all basic units in a non-closed form and fix them to the tooling; c) winding wire around the teeth of the basic unit; d) Wind all the basic units to form a stator core assembly.

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