Stator assembly, manufacturing method thereof and motor

Abstract

The invention provides a stator assembly and a manufacturing method thereof, and a motor, the stator assembly comprises a casing and a plurality of iron core blocks, each iron core block is assembled in the casing, each iron core block is spliced along the circumferential direction of the casing to form a stator core, each iron core block is provided with protrusions, the protrusions are distributed along the circumferential direction of the outer circumferential surface of the stator core at intervals, and the protrusions are arranged in the casing. A plurality of clamping grooves are formed in the machine shell, the clamping grooves are distributed in the circumferential direction of the machine shell at intervals, and the protrusions are clamped in the clamping grooves respectively. According to the invention, the stator iron core formed by the iron core blocks is automatically rounded by the aid of the casing, so that a mode of fixing the outer circle of the iron core through a tool is not needed, and the phenomenon that the outer diameter of the stator is rebounded to a certain degree or the outer circle of the stator is partially deformed due to the fact that the rounded tool is disassembled before the casing is sleeved is avoided. Therefore, the problem that the casing is difficult to sleeve or cannot be sleeved is solved.

Description

Technical Field

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

[0002] After the stator core is wound, it is assembled into the casing to form the motor stator assembly. The existing stator core can be divided into full circle type and block type according to its structural form. Compared with the block type, the full circle type is an integrated punching sheet with better cylindricity and coaxiality, but it has the disadvantages of low raw material utilization, high winding difficulty, and low slot fill rate. The existing block stator can eliminate the above disadvantages and improve the utilization rate of silicon steel sheets, but it is also difficult to control the precision of the inner circle coaxiality after rounding. The rounding method it adopts is to fix the outer circle of the core by tooling. This rounding method requires the rounding tooling to be disassembled before the casing is installed, which may cause a certain degree of rebound in the outer diameter of the stator, or partial deformation of the outer circle of the stator, which makes it difficult or impossible to install the casing. Summary of the invention

[0003] Therefore, the present invention provides a stator assembly, which can solve the technical problem that the block-type stator core adopts a rounding method of fixing the outer circle of the core by a tooling, and this rounding method requires the rounding tooling to be disassembled before the casing is installed, which causes a certain degree of rebound in the outer diameter of the stator or partial deformation of the outer circle of the stator, thereby making it difficult or impossible to install the casing.

[0004] In order to solve the above problems, the present invention provides a stator assembly, including a casing and a plurality of core blocks, each of the core blocks is assembled in the casing, and each of the core blocks is spliced ​​along the circumference of the casing to form a stator core, each of the core blocks is formed with a protrusion, and each of the protrusions is distributed at circumferential intervals along the outer peripheral surface of the stator core, and the casing is constructed with a plurality of slots, each of the slots is distributed at circumferential intervals along the casing, and each of the protrusions is respectively clamped in each of the slots.

[0005] In some embodiments, each of the slots passes through the housing, and each of the protrusions is respectively welded and fixed to the housing.

[0006] In some embodiments, two protrusions are formed on each of the core blocks, and the two protrusions are respectively distributed on the two side edges of the yoke of the core block, and two adjacent protrusions in two adjacent core blocks are clamped in the same clamping groove.

[0007] In some embodiments, the position where the protrusion meets the outer peripheral surface of the stator core is the root of the protrusion, and the width of the protrusion gradually decreases in the direction from the root of the protrusion to the free end of the protrusion.

[0008] In some embodiments, the sum of the widths of the roots of two adjacent protrusions in two adjacent core blocks is equal to the width of the slot.

[0009] In some embodiments, a groove is constructed on the inner circumferential surface of the casing, and along the axial direction of the stator core, the height of the groove is greater than or equal to the height of the core block, along the circumferential direction of the stator core, the width of the groove is greater than or equal to the width of the core block, and the groove is connected to any of the slots.

[0010] In some embodiments, one end of each of the slots extends to the first end of the housing; and / or each of the protrusions extends along the axial direction of the stator core, and each of the slots extends along the axial direction of the housing.

[0011] The present invention also provides a method for manufacturing the aforementioned stator assembly, comprising:

[0012] Step 1: putting the core blocks into the housing in sequence, splicing the core blocks to form the stator core, and clamping the protrusions into the slots respectively;

[0013] Step 2: placing a tire expansion tool on the radial inner side of the stator core;

[0014] Step 3: Welding and fixing each of the protrusions to the housing respectively;

[0015] Step 4: After welding is completed, take out the tire expansion tool.

[0016] The present invention also provides a motor, comprising the above-mentioned stator assembly.

[0017] In some embodiments, the motor further includes an end cover, and when one end of each of the slots extends to the first end of the housing, the end cover is provided with a plurality of spaced-apart stop structures along its circumference, the end cover is buckled onto the first end of the housing, and each of the stop structures is respectively snapped into each of the slots.

[0018] The present invention provides a stator assembly, a manufacturing method thereof, and a motor, which have the following beneficial effects:

[0019] The present application provides protrusions on each block-type core block, and constructs slots on the casing that are equal to the number of core blocks. After each core block is assembled into the casing, each protrusion is respectively snapped into each of the slots, thereby realizing direct installation and positioning of each core block and the casing, and then realizing that the stator core formed by each core block is automatically rounded with the help of the casing. In this way, there is no need to round the core outer circle by fixing the core outer circle with a tool, and there is no need to disassemble the rounding tool before installing the casing, which will cause a certain degree of rebound in the stator outer diameter or partial deformation of the stator outer circle, and then make it difficult or impossible to install the casing. At the same time, the rounding effect of each core block directly installed and positioned with the casing is better, which can improve the air gap roundness and uniformity of the stator core, thereby improving the motor noise, reducing the harmonic content, and improving the motor performance. Furthermore, the direct installation and positioning of each core block and the casing also eliminates the subsequent process of heating the casing and then shrink-fitting it onto the stator core formed by the core blocks, thereby simplifying the production process, reducing the investment in production equipment and tooling, and lowering production costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In order to more clearly illustrate the implementation methods of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for the implementation methods or the description of the prior art. Obviously, the drawings in the following description are only exemplary, and for ordinary technicians in this field, other implementation drawings can be derived from the provided drawings without creative work.

[0021] Figure 1 is a schematic diagram of a stator assembly according to an embodiment of the present invention;

[0022] Figure 2 for Figure 1 An enlarged schematic diagram of the stator assembly at A of an embodiment of the present invention;

[0023] Figure 3 This is a schematic diagram of a stator assembly without a casing according to an embodiment of the present invention;

[0024] Figure 4 for Figure 3 An enlarged schematic diagram of a stator assembly at B of an embodiment of the present invention;

[0025] Figure 5 Schematic diagram of a core block according to Embodiment 1 of the present invention;

[0026] Figure 6 is a schematic diagram of a core block according to a second embodiment of the present invention;

[0027] Figure 7 is a schematic diagram of a casing according to a first embodiment of the present invention;

[0028] Figure 8is a schematic diagram of a casing according to a second embodiment of the present invention;

[0029] Fig. 9 is a schematic diagram of an end cover according to an embodiment of the present invention;

[0030] Fig.10 It is a schematic diagram of an end cover buckled on a housing according to an embodiment of the present invention;

[0031] Fig.11 is a schematic diagram of a stator assembly in the prior art;

[0032] Fig.12 It is a schematic diagram of a stator assembly in the prior art without a casing;

[0033] Fig.13 It is a schematic diagram of an iron core block in the prior art;

[0034] Fig.14 It is a schematic diagram of a casing in the prior art.

[0035] The reference numerals are:

[0036] 1. Casing; 2. Core block; 3. Protrusion; 4. Slot; 5. Groove; 6. End cover; 7. Stop structure; 8. Positioning groove; 9. Positioning column; 10. Winding. DETAILED DESCRIPTION

[0037] 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 only part of the embodiments of the present invention, rather than all the embodiments. The following description of at least one exemplary embodiment is actually only illustrative and is by no means intended to limit the present invention and its application or use. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0038] In the description of the present invention, it is necessary to understand that the directions or positional relationships indicated by directional words such as "front, back, up, down, left, right", "lateral, vertical, perpendicular, horizontal" and "top, bottom" are usually based on the directions or positional relationships shown in the drawings. They are only for the convenience of describing the present invention and simplifying the description. Unless otherwise specified, these directional words do not indicate or imply that the devices or elements referred to must have a specific direction or be constructed and operated in a specific direction. Therefore, they cannot be understood as limiting the scope of protection of the present invention. The directional words "inside and outside" refer to the inside and outside relative to the contours of each component itself.

[0039] For ease of description, spatially relative terms such as "above", "above", "on the upper surface of", "above", etc. may be used here to describe the spatial positional relationship between a device or feature and other devices or features as shown in the figure. It should be understood that spatially relative terms are intended to include different orientations of the device in use or operation in addition to the orientation described in the figure. For example, if the device in the accompanying drawings is inverted, the device described as "above other devices or structures" or "above other devices or structures" will be positioned as "below other devices or structures" or "below other devices or structures". Thus, the exemplary term "above" can include both "above" and "below". The device can also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatially relative descriptions used here are interpreted accordingly.

[0040] In addition, it should be noted that the use of terms such as "first" and "second" to limit components is only for the convenience of distinguishing the corresponding components. If not otherwise stated, the above terms have no special meaning and therefore cannot be understood as limiting the scope of protection of the present invention.

[0041] See also Figures 1 to 14 As shown, according to an embodiment of the present invention, a stator assembly is provided, including a casing 1 and a plurality of core blocks 2, each of which is assembled in the casing 1, and each of the core blocks 2 is spliced ​​along the circumference of the casing 1 to form a stator core, a plurality of windings 10 are wound around the stator core, each of the core blocks 2 is formed with a protrusion 3, each of the protrusions 3 is distributed at intervals along the circumference of the outer circumference of the stator core, a plurality of slots 4 are constructed on the casing 1, each of the slots 4 is distributed at intervals along the circumference of the casing 1, and each of the protrusions 3 is respectively engaged in each of the slots 4.

[0042] In this technical solution, the present application sets a protrusion 3 on each block-type core block 2, constructs a slot 4 on the casing 1 that is equal to the number of the core blocks 2, and after each core block 2 is assembled into the casing 1, each protrusion 3 is respectively snapped into each slot 4, so as to realize the direct installation and positioning of each core block 2 and the casing 1, and then realize that the stator core formed by each core block 2 is automatically rounded with the help of the casing 1. In this way, there is no need to round the core outer circle by fixing the outer circle of the core with a tool, and there is no need to disassemble the rounding tool before installing the casing, which will cause a certain degree of rebound in the outer diameter of the stator or partial deformation of the outer circle of the stator, and then make it difficult or impossible to install the casing. At the same time, the rounding effect of each core block 2 directly installed and positioned with the casing 1 is better, which can improve the roundness and uniformity of the air gap of the stator core, thereby improving the motor noise, reducing the harmonic content, and improving the motor performance. Furthermore, the direct installation and positioning of each core block 2 and the casing 1 also eliminates the subsequent process of heating the casing and then shrink-fitting it onto the stator core formed by each core block 2, thereby simplifying the production process, reducing the investment in production equipment and tooling, and lowering production costs.

[0043] As a specific implementation, each of the slots 4 passes through the housing 1 , and each of the protrusions 3 is fixed to the housing 1 by welding.

[0044] In this embodiment, when each slot 4 penetrates the housing 1, welding can be performed from the outside of the housing 1. It should be noted that, for the rounding method of fixing the outer circle of the core with a tool, in order to improve the reliability of product quality, the connection between the housing 1 and the stator core is generally strengthened by pinning. However, the present application can cancel the pin reinforcement by welding each protrusion 3 to the housing 1, thereby reducing the motor parts and eliminating the need for pin drilling, further reducing the cost of the motor. Moreover, the pinning method of fixing the motor will inevitably cause the pin to loosen after the motor has been running for a long time, affecting the reliability of the motor, while the welding method of fixing the motor can always ensure the reliability of the connection between the housing 1 and the stator core. It should be noted that along the axial direction of the housing 1, the length of the slot 4 is slightly greater than the length of the protrusion 3, so that the protrusion 3 can be inserted into the slot 4, and the length of the slot 4 will not be too long, because the slot 4 is too long to be welded.

[0045] See also Figures 3 to 6As shown, two protrusions 3 are formed on each core block 2, and the two protrusions 3 are respectively distributed on the two side edges of the yoke of the core block 2, and the two adjacent protrusions 3 in two adjacent core blocks 2 are snapped into the same slot 4. In this way, each core block 2 can be stressed on both sides, which helps to balance the stress on each core block 2, and further helps to balance the overall stress on the stator core formed by splicing each core block 2. Preferably, the two protrusions 3 on each core block 2 are symmetrically distributed on each core block 2. Among them, positioning grooves 8 and positioning columns 9 are respectively formed on the two side surfaces of the yoke of each core block 2. After each core block 2 is spliced ​​to form the stator core, each positioning column 9 is respectively snapped into each positioning groove 8, so as to ensure that each core block 2 is accurately spliced ​​and aligned.

[0046] It can be understood that when two protrusions 3 are formed on each core block 2, each core block 2 can be welded and fixed to the casing 1 at two locations, which helps to improve the bonding strength between the core block 2 and the casing 1, and further helps to improve the bonding strength between the entire stator core and the casing 1.

[0047] See also Figures 3 to 6 As shown, the position where the protrusion 3 meets the outer peripheral surface of the stator core is the root of the protrusion 3, and the width of the protrusion 3 gradually decreases from the root of the protrusion 3 to the free end of the protrusion 3. Such a design of the protrusion 3 can make it easier for the protrusion 3 to be inserted into the slot 4, so that each core block 2 can be more easily assembled into the housing 1. More importantly, the gradual reduction in the width of the protrusion 3 also makes it possible for the protrusion 3 to occupy less space after the protrusion 3 is inserted into the slot 4, so that more solder can be filled into the slot 4, thereby enhancing the welding firmness between the protrusion 3 and the housing 1.

[0048] See also Figure 3 and Figure 4 As shown, the sum of the root widths of two adjacent protrusions 3 in two adjacent core blocks 2 is equal to the width of the slot 4, which can ensure the positioning accuracy of each core block 2 in the housing 1 and the strong connection between each core block 2 and the housing 1. That is, by designing the protrusion 3 to gradually reduce its width from the root to the free end and the sum of the root widths of the two protrusions 3 is equal to the width of the slot 4, the protrusion 3 is easily inserted into the slot 4, and each core block 2 is accurately positioned in the housing 1.

[0049] See also Figure 7 As shown, a groove 5 is constructed on the inner circumferential surface of the casing 1. Along the axial direction of the stator core, the height of the groove 5 is greater than or equal to the height of the core block 2. Along the circumferential direction of the stator core, the width of the groove 5 is greater than or equal to the width of the core block 2, and the groove 5 is connected to any slot 4.

[0050] In this technical solution, since the stator core formed by splicing the core blocks 2 is ultimately interference fit with the housing 1, during the process of assembling the core blocks 2 into the housing 1, the last 1 to 2 core blocks 2 to be placed will certainly be difficult to place. By constructing a groove 5 on the inner circumference of the housing 1, a certain amount of avoidance space can be created, making it easier to place the last 1 to 2 core blocks 2. The number of grooves 5 can be 1 to 2.

[0051] As another embodiment, Figure 8 As shown, one end of each slot 4 extends to the first end of the housing 1, which makes it easier for each core block 2 to be assembled into the housing 1. It is only necessary to align the protrusion 3 on each core block 2 with the slot 4 and slide it in. At the same time, such a design also makes it easier to place the last 1 to 2 core blocks 2 without having to construct a groove 5 on the inner circumference of the housing 1.

[0052] See also Figure 7 and Figure 8 As shown, each protrusion 3 extends along the axial direction of the stator core, and each slot 4 extends along the axial direction of the housing 1. This makes it easier to process each protrusion 3 and slot 4, and it is also easier to align each core block 2 when it is assembled into the housing 1.

[0053] The present invention also provides a method for manufacturing the aforementioned stator assembly, comprising:

[0054] Step 1: Place the core blocks 2 into the housing 1 in sequence, and splice the core blocks 2 to form a stator core, and snap the protrusions 3 into the slots 4 respectively;

[0055] Step 2: placing a tire expansion tool on the radial inner side of the stator core;

[0056] Step 3: Weld and fix each protrusion 3 to the housing 1 respectively;

[0057] Step 4: After welding is completed, remove the tire expansion tooling.

[0058] In this embodiment, by placing a tire expansion tool on the radial inner side of the stator core, the inner circle of the stator core can have a better rounding effect, so as to ensure that the inner circle cylindricality and coaxiality of the stator core meet the design requirements, further improve the air gap roundness, and further improve the motor noise and reduce the harmonic content. At the same time, the tire expansion tool also supports each core block 2, making it easier to weld each protrusion 3 and the housing 1. It is understandable that it is best to remove the tire expansion tool after the welding is completed and each weld is cold-treated, so as to prevent the stress between each core block 2 and the housing 1 from causing deformation of the stator assembly after the tire expansion tool is removed. Furthermore, after the cold treatment of each weld, it is necessary to perform beautification treatment such as painting.

[0059] It should also be noted that the core blocks 2 of the present application can ensure the accuracy of the stator core after being rounded through the slots 4 on the casing 1 and the tire expansion tooling, so the positioning grooves 8 and positioning columns 9 on the yoke of each core block 2 can be eliminated, thereby forming another core block 2 with a simple structure, such as Figure 6 shown.

[0060] The present invention also provides a motor, including an end cover 6 and the aforementioned stator assembly. When one end of each slot 4 extends to the first end of the casing 1, the end cover 6 is provided with a plurality of spaced-apart stop structures 7 along its circumference. The end cover 6 is buckled on the first end of the casing 1, and each stop structure 7 is respectively snapped into each slot 4.

[0061] In this technical solution, after each core block 2 is assembled into the housing 1, the multiple stopper structures 7 provided on the end cover 6 will block all the slots 4 on the housing 1, so that each protrusion 3 and each stopper structure 7 completely cover each slot 4. It is understandable that after the end cover 6 is buckled on the first end of the housing 1, each stopper structure 7 and the housing 1 will also be welded synchronously.

[0062] It is easy for those skilled in the art to understand that, without conflict, the advantageous technical features of the above-mentioned methods can be freely combined and superimposed.

[0063] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention shall be included in the protection scope of the present invention. The above are only preferred embodiments of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and variations can be made without departing from the technical principles of the present invention, and these improvements and variations should also be regarded as the protection scope of the present invention.

Claims

1. A stator assembly, characterized in that: The invention comprises a casing (1) and a plurality of core blocks (2), each of the core blocks (2) being assembled in the casing (1), and each of the core blocks (2) being spliced ​​along the circumference of the casing (1) to form a stator core, each of the core blocks (2) being formed with a protrusion (3), each of the protrusions (3) being distributed at intervals along the circumference of the outer circumference of the stator core, and a plurality of slots (4) being constructed on the casing (1), each of the slots (4) being distributed at intervals along the circumference of the casing (1), and each of the protrusions (3) being respectively engaged in each of the slots (4).

2. The stator assembly according to claim 1, characterized in that Each of the slots (4) penetrates the housing (1), and each of the protrusions (3) is respectively fixed to the housing (1) by welding.

3. The stator assembly according to claim 1 or 2, characterized in that: Two protrusions (3) are formed on each of the core blocks (2), and the two protrusions (3) are respectively distributed on the two side edges of the yoke of the core block (2), and the two adjacent protrusions (3) in two adjacent core blocks (2) are clamped in the same clamping groove (4).

4. The stator assembly according to claim 3, characterized in that: The position where the protrusion (3) meets the outer peripheral surface of the stator core is the root of the protrusion (3), and the width of the protrusion (3) gradually decreases in the direction from the root of the protrusion (3) to the free end of the protrusion (3).

5. The stator assembly according to claim 4, characterized in that: The sum of the widths of the roots of two adjacent protrusions (3) in two adjacent core blocks (2) is equal to the width of the slot (4).

6. The stator assembly according to claim 1, characterized in that A groove (5) is constructed on the inner circumferential surface of the housing (1); along the axial direction of the stator core, the height of the groove (5) is greater than or equal to the height of the core block (2); along the circumferential direction of the stator core, the width of the groove (5) is greater than or equal to the width of the core block (2); and the groove (5) is connected to any one of the slots (4).

7. The stator assembly according to claim 1, characterized in that One end of each of the slots (4) extends to the first end of the housing (1); and / or each of the protrusions (3) extends along the axial direction of the stator core, and each of the slots (4) extends along the axial direction of the housing (1).

8. A method for manufacturing a stator assembly according to any one of claims 1 to 7, characterized in that: include: Step 1: placing each of the core blocks (2) into the housing (1) in sequence, and splicing each of the core blocks (2) to form the stator core, and each of the protrusions (3) is respectively snapped into each of the slots (4); Step 2: placing a tire expansion tool on the radial inner side of the stator core; Step 3: Welding and fixing each of the protrusions (3) to the housing (1) respectively; Step 4: After welding is completed, take out the tire expansion tool.

9. A motor, characterized in that: A stator assembly comprising any one of claims 1 to 7.

10. The motor according to claim 9, characterized in that It also includes an end cover (6). When one end of each of the slots (4) extends to the first end of the housing (1), the end cover (6) is provided with a plurality of stop structures (7) spaced apart along its circumference. The end cover (6) is buckled onto the first end of the housing (1), and each of the stop structures (7) is respectively snapped into each of the slots (4).

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