Segmented stator core, electric machine and method for manufacturing stator assembly of electric machine

Abstract

The invention provides a segmented stator core for an electric machine. The segmented stator core includes a plurality of individual first teeth and a plurality of individual second teeth. The width of the first yoke end portion of the first tooth is smaller than or equal to the width of the first body so that the prefabricated winding component can be arranged on the first body in a sleeving mode through the first yoke end portion. A width of a second yoke end of the second tooth is greater than a width of the second body. The first teeth and the second teeth are configured to be arranged in a ring shape in the circumferential direction, so that each second tooth is arranged between two adjacent first teeth in the circumferential direction. The present application also provides a motor comprising the aforementioned segmented stator core, and a method for manufacturing a stator assembly of a motor. According to the present application, it is possible to easily and efficiently manufacture the stator assembly by using a combination of the prefabricated winding member and the tooth configuration, thereby reducing the process cost of the motor and improving the production efficiency.

Description

Segmented stator core, electric machine, and method for manufacturing a stator assembly of an electric machine Technical Field

[0001] The present application generally relates to the technical field of electric motors, and more particularly to a segmented stator core for an electric motor and an electric motor comprising the segmented stator core. The present application also relates to a method for manufacturing a stator assembly of an electric motor. Background Art

[0002] Electric motors are widely used in applications such as power generation and drive. They operate by exploiting the interaction of the magnetic fields of a rotor and stator rotating relative to each other. The stator consists of a stator core and stator windings. The stator windings are arranged around the teeth of the stator core and extend through the slots between the teeth to define the different electrical phases. In existing stator manufacturing processes, especially for stator cores with semi-closed slots, stator windings are typically wound around the teeth of the stator core using a winding process due to structural limitations. This winding process is complex and time-consuming, resulting in low production efficiency.

[0003] Therefore, it is necessary to improve the existing stator core to solve the above problems.

[0004] Summary of the Invention

[0005] The present application aims to provide an improved stator core to improve manufacturing efficiency.

[0006] According to one aspect of the present application, a segmented stator core for an electric motor is provided, characterized in that the segmented stator core comprises: a plurality of individual first teeth, each of the plurality of individual first teeth comprising a first yoke end and a first body extending radially from the first yoke end, the width of the first yoke end being less than or equal to the width of the first body to allow a prefabricated winding component to be sleeved onto the first body via the first yoke end; and a plurality of individual second teeth, each of the plurality of individual second teeth comprising a second yoke end and a second body extending radially from the second yoke end, the width of the second yoke end being greater than the width of the second body. The plurality of individual first teeth and the plurality of individual second teeth are arranged in a circular pattern along a circumferential direction, such that each second tooth in the plurality of individual second teeth is circumferentially disposed between two adjacent first teeth in the plurality of individual first teeth, wherein the second yoke end of each second tooth is connected to the first yoke ends of the two adjacent first teeth, and the second body of each second tooth defines a slot therebetween with the first bodies of the two adjacent first teeth for accommodating the prefabricated winding component.

[0007] In some embodiments, the first yoke end portion is integral with the first body and is made of a first grain-oriented steel, the rolling direction of the first grain-oriented steel being oriented along the radial direction, and the second yoke end portion is integral with the second body and is made of a second grain-oriented steel, the rolling direction of the second grain-oriented steel being oriented along the radial direction.

[0008] In some embodiments, the first yoke end portion is integral with the first body and is made of a first grain-oriented steel having its rolling direction oriented along the radial direction, and at least the second yoke end portion of the second tooth is made of a non-grain-oriented steel.

[0009] In some embodiments, the second yoke end portion is integral with the second body and is made of non-grain oriented steel.

[0010] In some embodiments, the second body is made of a second grain-oriented steel having a rolling direction oriented along the radial direction, and the second yoke end portion is fixed to the second body.

[0011] In some embodiments, the width of the first body is substantially uniform along the radial direction.

[0012] In some embodiments, the width of the second body gradually increases along the radially outward direction in the radial direction, so that the width of the groove is substantially uniform.

[0013] In some embodiments, the first body includes a first body side and a second body side opposite along the circumferential direction, the second body includes a third body side and a fourth body side opposite along the circumferential direction, the first yoke end includes a first yoke end side and a second yoke end side opposite along the circumferential direction, and the second yoke end includes a third yoke end side and a fourth yoke end side opposite along the circumferential direction, wherein: the first yoke end side is flush with the first body side in the circumferential direction, or is indented relative to the first body side in the circumferential direction; the second yoke end side is flush with the second body side in the circumferential direction, or is indented relative to the second body side in the circumferential direction; the third yoke end side extends beyond the third body side in the circumferential direction; and the fourth yoke end side extends beyond the fourth body side in the circumferential direction.

[0014] In some embodiments, when each of the multiple individual second teeth is circumferentially arranged between two adjacent first teeth among the multiple individual first teeth, the third body side of the second body of each second tooth is parallel to the first body side of the first body of one of the two adjacent first teeth, and the fourth body side of the second body is parallel to the second body side of the first body of the other of the two adjacent first teeth.

[0015] In some embodiments, the first yoke end portion further includes a groove recessed into the first yoke end portion from the first yoke end side and the second yoke end side, respectively, and the second yoke end portion further includes a protruding rib protruding from the third yoke end side and the fourth yoke end side, respectively. The protruding rib and the groove are configured such that when the first teeth and the second teeth are arranged along the circumferential direction, the protruding rib is received in the groove to guide and position the first teeth and the second teeth.

[0016] In some embodiments, each of the first teeth further includes a first tooth end portion opposite the first yoke end portion, the first body extending radially between the first yoke end portion and the first tooth end portion, and each of the second teeth further includes a second tooth end portion opposite the second yoke end portion, the second body extending radially between the second yoke end portion and the second tooth end portion. The second tooth end portion of each second tooth defines a gap therebetween with the first tooth ends of the two adjacent first teeth, and the width of each of the gaps is smaller than the width of the corresponding slot.

[0017] In some embodiments, the prefabricated winding component comprises a circular conductor prefabricated winding component, a rectangular conductor prefabricated winding component, or an elliptical conductor prefabricated winding component.

[0018] In some embodiments, the prefabricated winding component includes an insulating sleeve and a winding prefabricated on the insulating sleeve, wherein the insulating sleeve defines a sleeve portion therein, and the size of the sleeve portion is designed to be sleeved on the first body.

[0019] According to another aspect of the present application, an electric motor is provided, comprising a plurality of prefabricated winding components and the aforementioned segmented stator core, wherein each of the plurality of prefabricated winding components is sleeved on a corresponding first tooth among a plurality of first teeth of the segmented stator core.

[0020] According to another aspect of the present application, a method for manufacturing a stator assembly of an electric motor is provided, characterized in that the method comprises: providing a plurality of separate first teeth, each of the plurality of separate first teeth comprising a first yoke end portion and a first body extending radially from the first yoke end portion, wherein the width of the first yoke end portion is less than or equal to the width of the first body so as to allow a prefabricated winding component to be sleeved onto the first body via the first yoke end portion; providing a plurality of prefabricated winding components and sleeve each of the plurality of prefabricated winding components onto the first body via the first yoke end portion of a corresponding first tooth of the plurality of separate first teeth; providing a plurality of separate second teeth, the plurality of Each of the separate second teeth includes a second yoke end and a second body extending from the second yoke end along the radial direction, the width of the second yoke end is greater than the width of the second body; and the multiple separate first teeth and the multiple separate second teeth are arranged in a ring shape along the circumferential direction, so that each of the multiple separate second teeth is arranged between two adjacent first teeth among the multiple separate first teeth along the circumferential direction, wherein the second yoke end of each second tooth is respectively connected to the first yoke end of the two adjacent first teeth, and the second body of each second tooth is respectively defined with the first body of the two adjacent first teeth to accommodate the prefabricated winding component.

[0021] In some embodiments, the method includes forming the first yoke end portion and the first body integrally from a first grain-oriented steel, and orienting the rolling direction of the first grain-oriented steel along the radial direction, and forming the second yoke end portion and the second body integrally from a second grain-oriented steel, and orienting the rolling direction of the second grain-oriented steel along the radial direction.

[0022] In some embodiments, the method includes making the width of the first body substantially uniform along the radial direction, and gradually increasing the width of the second body along a radially outward direction in the radial direction, so that the width of the groove is substantially uniform.

[0023] In some embodiments, the method further includes: making the first yoke end portion and the first body integrally from a first grain-oriented steel, and orienting the rolling direction of the first grain-oriented steel along the radial direction; and making at least the second yoke end portion of the second tooth from a non-grain-oriented steel.

[0024] In some embodiments, the method further includes: making the second yoke end portion integrally with the second body from non-grain oriented steel; or making the second body from a second grain oriented steel, orienting the rolling direction of the second grain oriented steel along the radial direction, and fixing the second yoke end portion to the second body.

[0025] According to the present application, the stator assembly can be easily and efficiently manufactured by combining prefabricated winding components with a tooth configuration, thereby reducing the process cost of the motor and improving production efficiency. In addition, the hybrid tooth configuration using non-grain-oriented steel and grain-oriented steel can improve the performance of the manufactured motor stator, thereby improving the performance of the motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The above and other aspects of the present application will be more thoroughly understood and appreciated with reference to the accompanying drawings. It should be noted that the drawings are for illustrative purposes only and are not drawn to scale. In the drawings:

[0027] FIG1 schematically shows a structure of a motor including a segmented stator core according to a preferred embodiment of the present application from an axial perspective;

[0028] FIG2 is an axial view similar to FIG1 , but omitting other components including a prefabricated winding member to illustrate the assembled relationship between the first and second teeth of the segmented stator core;

[0029] FIG3 schematically illustrates an assembly method between a prefabricated winding component and a first tooth and a second tooth of a segmented stator core from an axial perspective, wherein the prefabricated winding component and the first tooth and the second tooth of the segmented stator core are in an exploded state;

[0030] FIG4 schematically shows another type of second teeth of a segmented stator core; and

[0031] FIG5 schematically shows the assembly steps of the segmented stator core and the winding components according to the preferred embodiment of the present application.

[0032] Reference Signs List

[0033] 1 motor

[0034] 3 Stator

[0035] 5 rotor

[0036] 7 Rotation axis

[0037] 9a,9b,9c,9d Radial

[0038] 100 segmented stator core

[0039] 101 First tooth

[0040] 101a First yoke end

[0041] 101b First Subject

[0042] 101c First tooth end

[0043] 102 Second tooth

[0044] 102a Second yoke end

[0045] 102b Second Subject

[0046] 102c Second tooth end

[0047] 103 slots

[0048] 104 grooves

[0049] 105 protruding ribs

[0050] 200 Prefabricated winding components

[0051] 201 Insulating Sleeve

[0052] 203 Winding

[0053] 1011 First main body side

[0054] 1012 Second main body side

[0055] 1013 First yoke end side

[0056] 1014 Second yoke end side

[0057] 1021 Third main body side

[0058] 1022 Fourth main body side

[0059] 1023 Third yoke end side

[0060] 1024 Fourth yoke end side

[0061] 1025 Swallowtail Rib

[0062] 1026 dovetail recess DETAILED DESCRIPTION

[0063] Some preferred embodiments of the present application are described in detail below with reference to examples. Those skilled in the art will appreciate that these embodiments are merely exemplary and are not intended to limit the present application in any way. In addition, the features in the embodiments of the present application may be combined with each other unless there is a conflict. It should be understood that the dimensions, proportional relationships, and number of components in the accompanying drawings are not intended to limit the present application.

[0064] FIG1 to FIG3 depict a segmented stator core 100 according to a preferred embodiment of the present application. FIG1 schematically illustrates, from an axial perspective, a partial structure of an electric motor 1 including the segmented stator core 100. FIG2 is an axial view similar to FIG1 , but omits other components, including a prefabricated winding member 200, to illustrate the assembly relationship between the first and second teeth 101, 102 of the segmented stator core 100. FIG3 schematically illustrates, from an axial perspective, a method for assembling the prefabricated winding member 200 with the first and second teeth 101, 102 of the segmented stator core 100, wherein the prefabricated winding member 200 and the first and second teeth 101, 102 of the segmented stator core are in an exploded state. For the sake of simplicity, the specific structure of the rotor 5 is not shown in detail in the drawings. Instead, FIG1 schematically illustrates only the relative positional relationship between the stator 3 and the rotor 5 of the electric motor 1, while omitting other components and structures. However, this does not mean that the electric motor 1, the stator 3, and the rotor 5 may not include other components or structures. The electric machine 1 operates by utilizing the interaction of the magnetic fields of the stator 3 and rotor 5 rotating relative to each other. For example, such an electric machine 1 may be an alternator, an alternator-starter, a traction motor, a hybrid drive motor, etc. As will be described below, the segmented stator core 100 can be assembled with a prefabricated winding component 200 to form a stator assembly. As used herein, a "prefabricated winding component" refers to a prefabricated component that carries a winding (such as winding 203 described below) that has been assembled before being mounted on a stator core to form a stator assembly.

[0065] The rotor 5 defines a rotation axis 7, which extends in a direction perpendicular to the paper in Figures 1 and 2. The rotor 5 is configured to rotate relative to the stator 3 about the rotation axis 7. In this application, unless otherwise specified, "axial" refers to the extending direction of the rotation axis 7, "radial" refers to the radial direction relative to the rotation axis 7, and "circumferential" refers to the circumferential direction relative to the rotation axis 7, that is, the direction surrounding the rotation axis 7. The radial directions are exemplarily indicated by "9a", "9b", "9c", and "9d" in Figures 1 and 2, and each radial direction 9a, 9b, 9c, and 9d includes a radially outward direction and a radially inward direction, wherein the radially outward direction refers to a radial direction pointing away from the rotation axis 7, and the radially inward direction refers to a radial direction pointing toward the rotation axis 7.

[0066] As shown in Figures 1 to 3, the segmented stator core 100 includes a plurality of individual first teeth 101 and a plurality of individual second teeth 102. "Individual teeth" means that each tooth, i.e., each of the first teeth 101 and the second teeth 102, is a single tooth separate from the other teeth. As best shown in Figure 2, each of the plurality of individual first teeth 101 includes a first yoke end 101a and a first body 101b extending from the first yoke end 101a in a radial direction (e.g., radial directions 9a and 9c). The first yoke end 101a and the first body 101b can each have a length, a width, and a thickness. In this application, unless otherwise specified, the "length" of the yoke end or body of a tooth refers to the dimension of the yoke end or body extending along the radial direction, the "width" refers to the dimension of the yoke end or body extending along the circumferential direction, and the "thickness" refers to the dimension of the yoke end or body extending along the axial direction.

[0067] Continuing with FIG2 , the width of the first yoke end portion 101a is configured to be equal to the width of the first body 101b to allow the prefabricated winding member 200 ( FIG1 and FIG3 ) to be sleeved onto the first body 101b via the first yoke end portion 101a. It should be understood that, although FIG2 illustrates the width of the first yoke end portion 101a as being equal to the width of the first body 101b, the width of the first yoke end portion 101a may also be configured to be smaller than the width of the first body 101b to allow the prefabricated winding member 200 to be sleeved onto the first body 101b via the first yoke end portion 101a. In other words, the configuration of the first tooth 101 enables the prefabricated winding member 200 to be easily and unimpededly sleeved onto the first body 101b via the first yoke end portion 101a.

[0068] Similar to the first tooth 101, each of the plurality of individual second teeth 102 includes a second yoke end 102a and a second body 102b extending radially (e.g., radial directions 9b and 9d) from the second yoke end 102a. However, unlike the first tooth 101, the width of the second yoke end 102a of the second tooth 102 is greater than the width of the second body 102b. The configuration of the second tooth 102 may hinder the prefabricated winding component 200 from being sleeved onto the first body 101b via the first yoke end 101a. As will be described below, the second tooth 102 is not configured for sleeved winding components 200 thereon.

[0069] While only two first teeth 101 and two second teeth 102 are shown in FIG1 and FIG2 , it should be understood that this is merely exemplary and that the segmented stator core 100 may have more first teeth 101 and second teeth 102 to form an annular structure. The plurality of individual first teeth 101 and the plurality of individual second teeth 102 of the segmented stator core 100 are arranged circumferentially in an annular configuration, such that each second tooth 102 is circumferentially disposed between two adjacent first teeth 101 (as best shown in FIG2 ). In other words, each pair of adjacent first teeth 101 shares a second tooth 102. The second yoke end 102a of each second tooth 102 is connected to the first yoke end 101a of two adjacent first teeth 101, and the second body 102b of each second tooth 102 defines a slot 103 therebetween with the first body 101b of two adjacent first teeth 101 for accommodating the prefabricated winding member 200.

[0070] By virtue of the aforementioned configuration of the first teeth 101 and the second teeth 102, the segmented stator core 100 can be easily and quickly assembled with a plurality of prefabricated winding components 200 to form a stator assembly, which serves as a portion of the stator 3. Specifically, during assembly, the prefabricated winding component 200 is first sleeved onto the first body 101b of the first tooth 101 via the first yoke end 101a of the first tooth 101 (as schematically indicated by arrow A in FIG3 ). Subsequently, the first tooth 101 and the second tooth 102, sleeved with the prefabricated winding component 200, are assembled together (as schematically indicated by arrows B1 and B2 in FIG3 ), thereby being circumferentially arranged in a ring in the aforementioned configuration. For example, the first teeth 101 and the second teeth 102 can be fixed to a stator core support (not shown) to hold the first teeth 101 and the second teeth 102 in position relative to each other.

[0071] It can be seen that the above-mentioned configuration of the first teeth 101 and the second teeth 102 of the segmented stator core 100 allows the stator 3 to be easily and efficiently manufactured using the prefabricated winding component 200, thereby reducing the process cost of the motor 1 and improving the production efficiency, especially when the motor 1 is a near-pole slot motor (the number of poles of such a motor is close to the number of slots).

[0072] Each of the first tooth 101 and the second tooth 102 can be formed from a plurality of laminations. The laminations are aligned and interconnected along the axial direction and stacked one on top of the other to form a complete tooth. The slots 103 can extend across the entire axial extent of the lamination stack. The laminations can be made of a ferromagnetic material. Suitable ferromagnetic materials for laminations include, but are not limited to, ferrosilicon and aluminum-iron alloys.

[0073] The present inventors have recognized that, for the aforementioned configuration of the first and second teeth 101, 102 of the segmented stator core 100, using grain-oriented steel (CRGO) to manufacture the first and second teeth 101, 102 can provide significant benefits. In other words, the present inventors have recognized that leveraging the properties of GRGO, combined with the aforementioned configuration of the first and second teeth 101, 102, can provide unexpected benefits. GRGO exhibits a fully anisotropic property, resulting in a significantly higher magnetic permeability in the rolling direction than in a direction perpendicular to the rolling direction. In other words, the magnetic permeability of GRGO varies in different directions, with the highest value in the rolling direction and the lowest value in a direction perpendicular to the rolling direction. Furthermore, GRGO exhibits the lowest iron loss in the rolling direction and can provide material iron loss characteristics superior to those of CRNGO (cold-rolled non-grain-oriented steel).

[0074] Since the first tooth 101 and the second tooth 102 are both separate teeth, this enables grain-oriented steel to be applied to each tooth to significantly improve the saturation magnetic flux density of the first tooth 101 and the second tooth 102. Specifically, the first yoke end 101a is integral with the first body 101b and is made of a first grain-oriented steel, and the rolling direction of the first grain-oriented steel is oriented along the radial direction (for example, radial 9a or 9c). The second yoke end 102a is integral with the second body 102b and is made of a second grain-oriented steel, and the rolling direction of the second grain-oriented steel is oriented along the radial direction (for example, radial 9b or 9d). In this way, compared to using grain-non-oriented steel to manufacture the first tooth 101 and the second tooth 102, using grain-oriented steel to manufacture the first tooth 101 and the second tooth 102 can significantly improve the saturation magnetic flux density of the first tooth 101 and the second tooth 102, thereby improving the torque density of the motor 1. Furthermore, the use of grain-oriented steel to manufacture the first and second teeth 101, 102 can significantly reduce the iron loss of the first and second teeth 101, 102. This can all improve the efficiency of the motor 1. Furthermore, because the yoke ends of the teeth are integral with the main body, i.e., can be manufactured as a single piece, this makes the manufacturing of the teeth easier and more efficient, thereby reducing process costs and improving production efficiency. In other words, combining the properties of grain-oriented steel with the above-described configuration of the first and second teeth 101, 102 can not only improve the production efficiency of the stator 3 and the motor 1 including the stator 3, but also improve the performance of the stator 3 and the motor 1 including the stator 3.

[0075] The inventors have further realized that although the use of grain-oriented steel to manufacture the first tooth 101 and the second tooth 102 can bring the aforementioned benefits, since the width of the second yoke end 102a of the second tooth 102 is greater than the width of the second body 102b (i.e., the second yoke end 102a protrudes beyond the second body 102b transversely to the radial direction), and due to the anisotropy of the grain-oriented steel, the magnetic permeability along the circumferential direction in the second yoke end 102a on the magnetic flux path is significantly lower than the magnetic permeability along the radial direction in the first tooth 101 (including the first yoke end 101a and the first body 101b) and the second body 102b, and the material iron loss characteristics along the circumferential direction in the second yoke end 102a are significantly greater than the material iron loss characteristics along the radial direction in the first tooth 101 (including the first yoke end 101a and the first body 101b) and the second body 102b.

[0076] In light of this, the present inventors further propose that at least the second yoke end 102a of the second tooth 102 be made of grain-non-oriented steel. Specifically, the first yoke end 101a is integrally formed with the first body 101b, and the first tooth 101 is made of first grain-oriented steel, the rolling direction of which is oriented radially (e.g., radial direction 9a or 9c), while at least the second yoke end 102a of the second tooth 102 is made of grain-non-oriented steel. This hybrid tooth configuration of grain-non-oriented steel and grain-oriented steel can further reduce iron loss in the yoke portion of the segmented stator core 100, thereby improving the performance of the stator 3 and the motor 1 including the stator 3. In other words, utilizing a hybrid tooth configuration comprising grain-non-oriented steel and grain-oriented steel can improve the production efficiency of the stator 3 and the motor 1 including the stator 3 while also improving the performance of the stator 3 and the motor 1 including the stator 3.

[0077] In some examples, as shown in Figures 2 and 3, the second yoke end 102a of the second tooth 102 is integrated with the second body 102b and is made of grain non-oriented steel. This configuration can well balance manufacturing efficiency and performance. In other partial examples, the second yoke end 102a of the second tooth 102 is made of grain non-oriented steel, while the second body 102b is made of second grain oriented steel, and the rolling direction of the second grain oriented steel is radially oriented. In this case, the second yoke end 102a and the second body 102b are manufactured separately and connected together. For example, Figure 4 schematically shows such a second tooth 102 configuration. As shown in Figure 4, the second yoke end 102a includes a dovetail-shaped protruding rib 1025 protruding in the radial direction, and the second body 102b includes a dovetail-shaped recess 1026 recessed in the second body 102b in the radial direction. During assembly, the second yoke end portion 102a and the second body 102b can be moved relative to each other in the axial direction so that the dovetail-shaped protruding rib 1025 is received in the dovetail-shaped recess 1026, thereby securing the second yoke end portion 102a to the second body 102b. It should be understood that the second yoke end portion 102a and the second body 102b can also be secured together using other suitable features, and the present application is not limited thereto.

[0078] It should be understood that the terms "first grain-oriented steel" and "second grain-oriented steel" are merely used to distinguish the grain-oriented steel used to manufacture the first tooth 101 from the grain-oriented steel used to manufacture the second tooth 102, but these grain-oriented steels should not be limited by such terms. The first grain-oriented steel and the second grain-oriented steel can be the same or different types of grain-oriented steel.

[0079] As shown in Figures 1 and 3, in some examples, the prefabricated winding component 200 includes an insulating sleeve 201 and a winding 203 prefabricated on the insulating sleeve 201. It should be understood that the winding 203 can be prefabricated on the insulating sleeve 201 using any process known in the art (as schematically indicated by arrow C in Figure 3). The insulating sleeve 201 can be hollow to define a sleeve portion (not shown) therein. The sleeve portion is sized to fit over the first body 101b of the first tooth 101. The insulating sleeve 201 can be fixed to the first body 101b using any means known in the art (e.g., snap fit, friction fit, using a fastener, etc.). The winding 203 is formed from an elongated conductor such as a copper magnetic conductor or a rod. The elongated conductor can be, for example, a circular conductor, a rectangular conductor, or an elliptical conductor. Accordingly, the prefabricated winding component 200 can be a circular conductor prefabricated winding component, a rectangular conductor prefabricated winding component, or an elliptical conductor prefabricated winding component. As used in this application, the terms "circular conductor," "rectangular conductor," and "elliptical conductor" refer to conductors having a circular, rectangular, or elliptical cross-sectional geometry, respectively, when viewed along a cross-sectional plane oriented perpendicular to the central axis of the conductor.

[0080] In some examples, as shown in FIG2 , the width of the first body 101b of the first tooth 101 can be substantially uniform along the radial direction. In the present application, unless otherwise specified, the expression "substantially" means within the range allowed by manufacturing tolerances. It should be understood that the width of the first body 101b can also vary along the radial direction, as long as it does not hinder the prefabricated winding member 200 from being mounted thereon, and the present application is not limited thereto. As shown in FIG1 and FIG2 , the width of the second body 102b of the second tooth 102 gradually increases along the radially outward direction in the radial direction (i.e., the radial direction pointing away from the axis of rotation 7). It should be understood that the width of the second body 102b can also vary along the radial direction, and the present application is not limited thereto.

[0081] In one of these examples, as shown in FIG2 , the width of the first body 101b of the first tooth 101 is substantially uniform along the radial direction, and the width of the second body 102b of the second tooth 102 gradually increases in the radially outward direction, so that the width of the slot 103 is substantially uniform. This helps to improve the slot fill factor (or "slot filling factor") when the prefabricated winding component 200 is placed in the slot 103, and reduces copper loss, thereby improving the efficiency of the motor 1, especially when using prefabricated winding components with rectangular conductors.

[0082] It should be understood that although the segmented stator core 100 is shown in FIG1 as being configured for an inner stator configuration (i.e., the rotor 5 is radially outside the stator 3 and the yoke end of the tooth is the radially inner end of the tooth), the segmented stator core 100 may also be configured for an outer stator configuration (i.e., the rotor 5 is radially inside the stator 3 and the yoke end of the tooth is the radially outer end of the tooth). In the case where the segmented stator core 100 is configured for an outer stator configuration, the width of the first body 101b of the first tooth 101 may also be substantially uniform along the radial direction, and the width of the second body 102b of the second tooth 102 may also gradually increase in the radially outward direction in the radial direction, so that the width of the slot 103 is substantially uniform. Similar to the case where the segmented stator core 100 is configured for an inner stator configuration, when the segmented stator core 100 is configured for an outer stator configuration, this also helps to improve the slot fill rate when the prefabricated winding components 200 are arranged in the slots 103 and reduce copper losses, thereby improving the efficiency of the motor 1, especially for the case where rectangular conductor prefabricated winding components are used.

[0083] Continuing with Figures 2 and 3 , the first body 101b of the first tooth 101 includes a first body side 1011 and a second body side 1012 that are opposite in the circumferential direction, and the first yoke end portion 101a includes a first yoke end side 1013 and a second yoke end side 1014 that are opposite in the circumferential direction. The second body 102b of the second tooth 102 includes a third body side 1021 and a fourth body side 1022 that are opposite in the circumferential direction, and the second yoke end portion 102a includes a third yoke end side 1023 and a fourth yoke end side 1024 that are opposite in the circumferential direction. The first yoke end side 1013 may be circumferentially flush with the first body side 1011 or may be circumferentially recessed relative to the first body side 1011. Furthermore, the second yoke end side 1014 may be circumferentially flush with the second body side 1012 or may be circumferentially recessed relative to the second body side 1012. This configuration of the first tooth 101 allows the prefabricated winding component 200 to be sleeved onto the first body 101b via the first yoke end 101a. The third yoke end side 1023 extends circumferentially beyond the third body side 1021, and the fourth yoke end side 1024 extends circumferentially beyond the fourth body side 1022. Due to this configuration of the second tooth 102, the prefabricated winding component 200 cannot be sleeved onto the second body 102b via the second yoke end 102a. However, due to this configuration of the second teeth 102, when each second tooth 102 in the plurality of individual second teeth 102 is circumferentially disposed between two adjacent first teeth 101 in the plurality of individual first teeth 101, as shown in FIG2 , the second yoke end 102a of each second tooth 102 can be connected to the first yoke end 101a of each of the two adjacent first teeth 101, and the second body 102b of each second tooth 102 can define therebetween a slot 103 for accommodating the prefabricated winding member 200 with the first body 101b of each of the two adjacent first teeth 101. As shown in FIG2 , the third body side 1021 of the second body 102b of the second tooth 102 defines the slot 103 with the first body side 1011 of the first body 101b of one adjacent first tooth 101, and the fourth body side 1022 of the second body 102b of the second tooth 102 defines the slot 103 with the second body side 1012 of the first body 101b of the other adjacent first tooth 101.

[0084] In some examples, as shown in FIG2 , when each second tooth 102 in the plurality of individual second teeth 102 is circumferentially disposed between two adjacent first teeth 101 in the plurality of individual first teeth 101, the third body side 1021 of the second body 102b of each second tooth 102 is parallel to the first body side 1011 of the first body 101b of one of the two adjacent first teeth 101, and the fourth body side 1022 of the second body 102b is parallel to the second body side 1012 of the first body 101b of the other of the two adjacent first teeth 101. With this configuration, the width of the slot 103 can be made substantially uniform. This helps to increase the slot fill rate and reduce copper loss when the prefabricated winding member 200 is disposed in the slot 103, thereby improving the efficiency of the motor 1, particularly when using a prefabricated winding member with a rectangular conductor.

[0085] In some examples, as shown in Figures 1 to 3, the first and second teeth 101, 102 may include mating features that help guide and position the first and second teeth 101, 102 when the first and second teeth 101, 102 are arranged circumferentially. Specifically, the first yoke end 101a of the first tooth 101 includes a groove 104 that is recessed into the first yoke end 101a from the first and second yoke end sides 1013, 1014, respectively, and the second yoke end 102a of the second tooth 102 includes a protruding rib 105 that protrudes from the third and fourth yoke end sides 1023, 1024, respectively. The protruding rib 105 and the groove 104 are configured such that when the first and second teeth 101, 102 are arranged circumferentially, the protruding rib 105 is received in the groove 104 to guide and position the first and second teeth 101, 102. By means of the protruding ribs 105 and the grooves 104 , the first teeth 101 and the second teeth 102 can be accurately positioned and held in position relative to each other, thereby improving assembly efficiency and structural reliability of the segmented stator core 100 .

[0086] As shown in Figures 1 to 3, the first tooth 101 further includes a first tooth end 101c opposite the first yoke end 101a, with the first body 101b extending radially between the first yoke end 101a and the first tooth end 101c. The second tooth 102 further includes a second tooth end 102c opposite the second yoke end 102a, with the second body 102b extending radially between the second yoke end 102a and the second tooth end 102c. In some examples, as shown in Figures 1 to 3, the second tooth end 102c of each second tooth 102 defines a gap therebetween with the first tooth ends 101c of two adjacent first teeth 101, with the width (i.e., circumferential dimension) of each gap being less than the width of the corresponding slot 103. In this manner, the slots 103 are formed as semi-closed slots or nearly fully closed slots (since the first tooth 101 and the second tooth 102 are teeth separated at the tooth ends, the slots 103 are not fully closed). For example, as shown in FIG2 , the first tooth end 101c of the first tooth 101 and the second tooth end 102c of the second tooth 102 protrude from the first and second main body sides 1011, 1012 of the first tooth 101, and the third and fourth main body sides 1021, 1022 of the second tooth 102, respectively, and extend circumferentially toward each other. This tooth end configuration of the first and second teeth 101, 102 helps reduce the drop in magnetic flux density at the tooth ends, thereby helping to improve the efficiency of the motor 1. Furthermore, with this tooth end configuration, since the first and second teeth 101, 102 have the yoke end configuration described above, it is still possible to use a prefabricated winding component 200 to manufacture the stator 3. This makes it easier and more efficient to manufacture a high-performance motor 1 compared to the prior art.

[0087] The present inventors have also proposed an electric motor 1 including the aforementioned segmented stator core 100. This electric motor 1 may include a plurality of prefabricated winding components 200 and the aforementioned segmented stator core 100. Each of the plurality of prefabricated winding components 200 is sleeved onto a corresponding first tooth 101 among the plurality of first teeth 101 of the segmented stator core 100. No winding is provided on the second teeth 102. The prefabricated winding components 200 may be connected in a manner known in the art to define different electrical phases. As described above, this electric motor 1 achieves a good balance between manufacturing efficiency and performance.

[0088] The present inventors have also proposed a method for manufacturing a stator assembly including the aforementioned segmented stator core 100. Specifically, as schematically shown in FIG5 , the method includes: in step S1, providing a plurality of individual first teeth 101, each of the plurality of individual first teeth 101 including a first yoke end 101a and a first main body 101b extending radially from the first yoke end 101a, the width of the first yoke end 101a being less than or equal to the width of the first main body 101b, so as to allow a prefabricated winding component 200 to be sleeved onto the first main body 101b via the first yoke end 101a; next, in step S2, providing a plurality of prefabricated winding components 200 and sleeve each of the plurality of prefabricated winding components 200 onto the first main body 101b via the first yoke end 101a of a corresponding first tooth 101 in the plurality of individual first teeth 101; next, in step S3, providing a plurality of individual second teeth 102, the plurality of individual second teeth 103 being sleeved onto the first main body 101b via the first yoke end 101a; Each second tooth 102 in the plurality of first teeth 101 includes a second yoke end 102a and a second body 102b extending radially from the second yoke end 102a, wherein the width of the second yoke end 102a is greater than the width of the second body 102b. Next, in step S4, the plurality of individual first teeth 101 and the plurality of individual second teeth 102 are arranged in a ring shape in the circumferential direction, so that each second tooth 102 in the plurality of individual second teeth 102 is circumferentially disposed between two adjacent first teeth 101 in the plurality of individual first teeth 101, wherein the second yoke end 102a of each second tooth 102 is respectively connected to the first yoke end 101a of the two adjacent first teeth 101, and the second body 102b of each second tooth 102 is respectively connected to the first body 101b of the two adjacent first teeth 101 to define a slot 103 therebetween for accommodating the prefabricated winding member 200. As described above, this method can easily and efficiently manufacture a stator assembly by combining the prefabricated winding member with the tooth configuration, thereby reducing the process cost of the stator assembly and improving production efficiency. It should be understood that in some embodiments, some of the steps may not be performed in the order described above. For example, step S3 may be performed first, and then steps S1, S2, and S4 may be performed in sequence.

[0089] In some embodiments, the method further includes: integrally forming the first yoke end portion 101a and the first main body 101b from a first grain-oriented steel, and orienting the rolling direction of the first grain-oriented steel along the radial direction, and integrally forming the second yoke end portion 102a and the second main body 102b from a second grain-oriented steel, and orienting the rolling direction of the second grain-oriented steel along the radial direction.

[0090] In some embodiments, the method further includes making the width of the first body 101b substantially uniform along the radial direction, and gradually increasing the width of the second body 102b along the radially outward direction in the radial direction, so that the width of the groove 103 is substantially uniform.

[0091] In some embodiments, the method further includes: integrally forming the first yoke end portion 101a and the first body 101b from a first grain-oriented steel, with the rolling direction of the first grain-oriented steel being oriented in a radial direction; and forming at least the second yoke end portion 102a of the second tooth 102 from a non-grain-oriented steel. Forming at least the second yoke end portion 102a of the second tooth 102 from the non-grain-oriented steel includes integrally forming the second yoke end portion 102a and the second body 102b from the non-grain-oriented steel. Alternatively, forming at least the second yoke end portion 102a of the second tooth 102 from the non-grain-oriented steel includes forming the second body 102b from a second grain-oriented steel, with the rolling direction of the second grain-oriented steel being oriented in a radial direction, and fixing the second yoke end portion 102a to the second body 102b.

[0092] It will be understood that the terms “first,” “second,” “third,” and “fourth” are only used to distinguish one element or portion from another element or portion, but these elements and / or portions should not be limited by such terms.

[0093] The present application has been described in detail above with reference to specific embodiments. It is apparent that the above description and the embodiments shown in the accompanying drawings are to be understood as illustrative only and do not constitute limitations on the present application. Those skilled in the art may make various modifications or alterations to the present application without departing from the spirit of the present application, and such modifications or alterations do not depart from the scope of the present application.

Claims

1. A segmented stator core (100) for an electric motor, characterized in that: The segmented stator core (100) comprises: a plurality of separate first teeth (101), each of the plurality of separate first teeth (101) comprising a first yoke end portion (101a) and a first body (101b) extending radially from the first yoke end portion (101a), wherein a width of the first yoke end portion (101a) is less than or equal to a width of the first body (101b), so as to allow a prefabricated winding component (200) to be sleeved onto the first body (101b) via the first yoke end portion (101a); and a plurality of separate second teeth (102), each second tooth (102) of the plurality of separate second teeth (102) comprising a second yoke end portion (102a) and a second body (102b) extending from the second yoke end portion (102a) in the radial direction, the second yoke end portion (102a) having a width greater than a width of the second body (102b); The plurality of separate first teeth (101) and the plurality of separate second teeth (102) are configured to be arranged in a ring along the circumferential direction, so that each second tooth (102) of the plurality of separate second teeth (102) is arranged between two adjacent first teeth (101) of the plurality of separate first teeth (101) along the circumferential direction, wherein the second yoke end (102a) of each second tooth (102) is respectively connected to the first yoke end (101a) of the two adjacent first teeth (101), and the second body (102b) of each second tooth (102) and the first body (101b) of the two adjacent first teeth (101) define a slot (103) therebetween for accommodating a prefabricated winding component (200).

2. The segmented stator core (100) according to claim 1, characterized in that: The first yoke end portion (101a) is integral with the first body (101b) and is made of a first grain-oriented steel, the rolling direction of the first grain-oriented steel being oriented along the radial direction; and The second yoke end portion (102a) is integral with the second body (102b) and is made of a second grain-oriented steel having a rolling direction oriented along the radial direction.

3. The segmented stator core (100) according to claim 1, characterized in that: The first yoke end portion (101a) is integral with the first body (101b) and is made of a first grain-oriented steel, the rolling direction of the first grain-oriented steel being oriented along the radial direction; and At least the second yoke end portion (102a) of the second tooth (102) is made of non-grain-oriented steel.

4. The segmented stator core (100) according to claim 3, characterized in that: The second yoke end portion (102a) is integral with the second body (102b) and is made of non-grain oriented steel; or The second body (102b) is made of a second grain-oriented steel having a rolling direction oriented along the radial direction, and the second yoke end portion (102a) is fixed to the second body (102b).

5. The segmented stator core (100) according to claim 1, characterized in that The width of the first body (101b) is substantially uniform along the radial direction.

6. The segmented stator core (100) according to claim 5, characterized in that The width of the second body (102b) gradually increases in a radially outward direction in the radial direction, so that the width of the groove (103) is substantially uniform.

7. The segmented stator core (100) according to claim 1, characterized in that The first body (101b) includes a first body side (1011) and a second body side (1012) opposite to each other along the circumferential direction, the second body (102b) includes a third body side (1021) and a fourth body side (1022) opposite to each other along the circumferential direction, the first yoke end portion (101a) includes a first yoke end side (1013) and a second yoke end side (1014) opposite to each other along the circumferential direction, and the second yoke end portion (102a) includes a third yoke end side (1023) and a fourth yoke end side (1024) opposite to each other along the circumferential direction, wherein: The first yoke end side (1013) is flush with the first main body side (1011) in the circumferential direction, or is retracted relative to the first main body side (1011) in the circumferential direction; The second yoke end side (1014) is flush with the second main body side (1012) in the circumferential direction, or is retracted relative to the second main body side (1012) in the circumferential direction; The third yoke end side (1023) extends beyond the third main body side (1021) in the circumferential direction; and The fourth yoke end side (1024) extends beyond the fourth main body side (1022) in the circumferential direction.

8. The segmented stator core (100) according to claim 7, characterized in that When each second tooth (102) of the plurality of individual second teeth (102) is circumferentially arranged between two adjacent first teeth (101) of the plurality of individual first teeth (101), the third body side (1021) of the second body (102b) of each second tooth (102) is parallel to the first body side (1011) of the first body (101b) of one first tooth (101) of the two adjacent first teeth (101), and the fourth body side (1022) of the second body (102b) is parallel to the second body side (1012) of the first body (101b) of the other first tooth (101) of the two adjacent first teeth (101).

9. The segmented stator core (100) according to claim 7, characterized in that: The first yoke end portion (101a) further includes a groove (104) recessed into the first yoke end portion (101a) from the first yoke end side (1013) and the second yoke end side (1014), respectively; and The second yoke end portion (102a) further includes protruding ribs (105) protruding from the third yoke end side (1023) and the fourth yoke end side (1024) respectively; The protruding rib (105) and the groove (104) are configured such that when the first tooth (101) and the second tooth (102) are arranged along the circumferential direction, the protruding rib (105) is received in the groove (104) to guide and position the first tooth (101) and the second tooth (102).

10. The segmented stator core (100) according to claim 1, characterized in that: Each of the first teeth (101) further includes a first tooth end portion (101c) opposite to the first yoke end portion (101a), and the first body (101b) extends between the first yoke end portion (101a) and the first tooth end portion (101c) in the radial direction; and Each of the second teeth (102) further includes a second tooth end portion (102c) opposite to the second yoke end portion (102a), and the second body (102b) extends between the second yoke end portion (102a) and the second tooth end portion (102c) in the radial direction; The second tooth end portion (102c) of each second tooth (102) defines a gap with the first tooth end portions (101c) of the two adjacent first teeth (101), and the width of each of the gaps is smaller than the width of the corresponding slot (103).

11. The segmented stator core (100) according to claim 1, characterized in that: The prefabricated winding component (200) comprises a circular conductor prefabricated winding component, a rectangular conductor prefabricated winding component or an elliptical conductor prefabricated winding component; and / or The prefabricated winding component (200) comprises an insulating sleeve (201) and a winding (203) prefabricated on the insulating sleeve (201), wherein the insulating sleeve (201) defines a sleeve portion, and the size of the sleeve portion is designed to be suitable for being sleeved on the first body (101b).

12. A motor, characterized in that: The motor comprises: a plurality of prefabricated winding components (200); and The segmented stator core (100) according to any one of claims 1 to 11; Each of the plurality of prefabricated winding components (200) is sleeved on a corresponding first tooth (101) among a plurality of first teeth (101) of the segmented stator core (100).

13. A method for manufacturing a stator assembly of an electric motor, characterized in that: The method comprises: Providing a plurality of separate first teeth (101), each of the plurality of separate first teeth (101) comprising a first yoke end portion (101a) and a first body (101b) extending radially from the first yoke end portion (101a), wherein the width of the first yoke end portion (101a) is less than or equal to the width of the first body (101b), so as to allow a prefabricated winding component (200) to be sleeved onto the first body (101b) via the first yoke end portion (101a); Providing a plurality of prefabricated winding members (200) and sleeve each of the plurality of prefabricated winding members (200) onto a first body (101b) via a first yoke end (101a) of a corresponding first tooth (101) of the plurality of individual first teeth (101); providing a plurality of separate second teeth (102), each second tooth (102) of the plurality of separate second teeth (102) comprising a second yoke end portion (102a) and a second body (102b) extending from the second yoke end portion (102a) in the radial direction, the second yoke end portion (102a) having a width greater than a width of the second body (102b); and The plurality of separate first teeth (101) and the plurality of separate second teeth (102) are arranged in a ring shape along the circumferential direction, so that each second tooth (102) of the plurality of separate second teeth (102) is arranged between two adjacent first teeth (101) of the plurality of separate first teeth (101) along the circumferential direction, wherein the second yoke end (102a) of each second tooth (102) is respectively connected to the first yoke end (101a) of the two adjacent first teeth (101), and the second body (102b) of each second tooth (102) is respectively defined with the first body (101b) of the two adjacent first teeth (101) to define a slot (103) therebetween to accommodate the prefabricated winding component (200).

14. The method according to claim 13, characterized in that The method further comprises: The first yoke end portion (101a) and the first body (101b) are integrally made of a first grain-oriented steel, and the rolling direction of the first grain-oriented steel is oriented along the radial direction; and The second yoke end portion (102a) and the second body (102b) are integrally made of a second grain-oriented steel, and a rolling direction of the second grain-oriented steel is oriented along the radial direction.

15. The method according to claim 13, characterized in that The method further comprises: The first yoke end portion (101a) and the first body (101b) are integrally made of a first grain-oriented steel, and the rolling direction of the first grain-oriented steel is oriented along the radial direction; and At least the second yoke end portion (102a) of the second tooth (102) is made of non-grain-oriented steel.

16. The method according to claim 15, characterized in that The method further comprises: The second yoke end portion (102a) and the second body (102b) are integrally made of non-grain oriented steel; or The second body (102b) is made of a second grain-oriented steel with a rolling direction of the second grain-oriented steel oriented along the radial direction, and the second yoke end portion (102a) is fixed to the second body (102b).

17. The method according to claim 13, wherein The method further comprises: The width of the first body (101b) is made substantially uniform along the radial direction, and the width of the second body (102b) is made gradually larger in a radially outward direction in the radial direction, so that the width of the groove (103) is made substantially uniform.

Images