Motor stator, manufacturing method thereof and motor

Abstract

The invention relates to a motor stator, a manufacturing method thereof and a motor. The motor stator comprises a stator core, a plurality of coil holders, a plurality of first profiled coils and a plurality of second profiled coils. The stator core comprises a plurality of single teeth which are sequentially spliced along the circumference to form a whole circle. Each single tooth is coated with a wire frame, and a wire winding groove is formed in each wire frame. A first profiled coil is wound in the winding groove in one of any two adjacent single teeth, and a second profiled coil is wound in the winding groove in the other single tooth; in the radial direction of the stator core, the first profiled coil is provided with a first convex part and a first concave part which are arranged in sequence, the second profiled coil is provided with a second concave part and a second convex part which are arranged in sequence, and the first convex part of the first profiled coil is arranged in the second concave part of the adjacent second profiled coil. And the second convex part of the second profiled coil is arranged in the first concave part of the adjacent first profiled coil. According to the motor stator, the slot fullness rate can be improved, and the miniaturization requirement of a joint motor is met.

Description

Technical Field

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

[0002] With the rapid development of new energy, logistics and other industries, the requirements for collaborative robots are getting higher and higher, such as longer arm span, greater load capacity, faster operation rhythm, etc. This requires the motors of each joint of the collaborative robot to have higher performance, such as greater torque, faster speed, etc.

[0003] In related technologies, for safety reasons, collaborative robot systems usually use a low voltage of 48V. In order to further increase the motor power, a high current design is required, and the motor coil needs to be wound with thicker enameled wire. However, as the enameled wire becomes thicker, coil winding becomes more and more difficult, the manufacturing process becomes complicated, and the slot fill rate decreases. The motor is large in size and cannot meet the needs of miniaturization of joint motors. Summary of the invention

[0004] Based on this, it is necessary to provide a motor stator, a manufacturing method thereof and a motor to address the problems that the coil slot fill rate of the above-mentioned low-voltage and high-current motor is reduced, the manufacturing process is complex, and the demand for miniaturization of the joint motor cannot be met.

[0005] In a first aspect, the present application provides a motor stator, comprising:

[0006] The stator core comprises a plurality of single teeth which are sequentially spliced ​​along the circumference to form a full circle;

[0007] A plurality of wire racks, each of the single teeth is covered with the wire rack, and the wire rack is formed with a winding groove;

[0008] A plurality of first profiled coils and a plurality of second profiled coils, wherein the first profiled coil is wound in the winding groove on one of any two adjacent single teeth, and the second profiled coil is wound in the winding groove on the other of the two adjacent single teeth;

[0009] Among them, along the radial direction of the stator core, the first corrugated coil has a first convex portion and a first concave portion arranged in sequence, and the second corrugated coil has a second concave portion and a second convex portion arranged in sequence, the first convex portion of the first corrugated coil is arranged in the second concave portion of the adjacent second corrugated coil, and the second convex portion of the second corrugated coil is arranged in the first concave portion of the adjacent first corrugated coil.

[0010] In some embodiments, two adjacent turns of the winding cables of the first corrugated coil are in surface contact with each other, and two adjacent turns of the winding cables of the second corrugated coil are in surface contact with each other; and / or, the winding cable of the first corrugated coil is in surface contact with the single tooth, and the winding cable of the second corrugated coil is in surface contact with the single tooth.

[0011] In some embodiments, the cross-sectional shape of the winding cables of the first and second profiled coils is non-circular.

[0012] In some embodiments, the single tooth includes a yoke and a tooth, the yoke is spliced ​​in sequence to form the outer ring of the stator core, the tooth includes a tooth stem connected to the yoke and a pole shoe connected to the tooth stem, and the pole shoes are arranged at intervals to form the inner ring of the stator core; the winding groove is located between the yoke and the pole shoe; the first protrusion and the second recess are arranged close to the yoke, and the second protrusion and the first recess are arranged close to the pole shoe.

[0013] In some embodiments, the first pressed coil has a first winding start and a first winding end, and the first winding start and the first winding end are arranged close to the yoke of the single tooth; the second pressed coil has a second winding start and a second winding end, and the second winding start and the second winding end are arranged close to the pole shoe of the single tooth.

[0014] In some embodiments, the motor stator also includes a terminal board, which has a plurality of wiring holes, and the opening positions of the plurality of wiring holes match the setting positions of the plurality of first winding starting ends, the plurality of first winding endings, the plurality of second winding starting ends and the plurality of second winding endings; the plurality of first winding starting ends, the plurality of first winding endings, the plurality of second winding starting ends and the plurality of second winding endings are respectively passed through the corresponding wiring holes.

[0015] In a second aspect, the present application provides a method for manufacturing a motor stator, for manufacturing the motor stator as described in any one of the first aspects, the method for manufacturing the motor stator comprising:

[0016] Winding a first coil on a single tooth of the coated bobbin to obtain a first winding monomer; winding a second coil on a single tooth of the coated bobbin to obtain a second winding monomer;

[0017] Using a first pressing mold to press the first winding monomer to obtain a first stator monomer; using a second pressing mold to press the second winding monomer to obtain a second stator monomer;

[0018] A plurality of first stator monomers and a plurality of second stator monomers are alternately spliced ​​along the circumference to form a full circle, thereby obtaining an assembled body of the motor stator.

[0019] In some embodiments, the step of winding a first coil on a single tooth of the coated bobbin to obtain a first winding monomer includes:

[0020] Determine the wire diameter and number of windings of the winding cable of the first coil according to the motor power;

[0021] On the single tooth wrapped with the wire frame, the yoke close to the single tooth is used as the winding starting point and winding end point, and the winding cable is sequentially wound in the winding groove along the extension direction of the tooth stem of the single tooth and wound multiple layers from the inside to the outside to form a first coil, and the number of winding layers close to the yoke of the first coil is greater than the number of winding layers close to the pole shoe, thereby obtaining a first winding monomer;

[0022] The step of winding a second coil on a single tooth of the coated bobbin to obtain a second winding monomer comprises:

[0023] Determine the wire diameter and number of windings of the winding cable of the second coil according to the motor power;

[0024] On a single tooth wrapped with a wire frame, the pole shoe close to the single tooth is used as the winding starting point and winding end point, and the winding cable is wound in the winding groove in sequence along the extension direction of the tooth stem of the single tooth and wound in multiple layers from the inside to the outside to form a second coil, and the number of winding layers of the second coil close to the pole shoe is greater than the number of winding layers close to the yoke, thereby obtaining a second winding monomer.

[0025] In some embodiments, the step of using a first profiling die to perform profiling on the first winding monomer to obtain a first stator monomer includes:

[0026] Fixing the first winding monomer in the first pressing mold;

[0027] The first forming mold is driven to form a first winding monomer, and during the forming process, a high-frequency current is simultaneously passed through the winding cable of the first winding monomer to preheat the winding cable, so as to form the first coil into a first forming coil, thereby obtaining a first stator monomer;

[0028] The method of using a second profiling die to perform profiling on the second winding monomer to obtain a second stator monomer comprises:

[0029] Fixing the second winding monomer in the second pressing die;

[0030] The second pressing mold is driven to press the second winding monomer, and during the pressing process, a high-frequency current is simultaneously passed through the winding cable of the second winding monomer for preheating, so as to press the second coil into a second pressed coil, thereby obtaining a second stator monomer.

[0031] In a third aspect, the present application provides a motor, comprising a motor stator as described in any one of the first aspects.

[0032] The above-mentioned motor stator, its manufacturing method and motor, by adopting a profiled coil, greatly reduces the gap between the winding cables, and the winding slot is almost completely filled with the winding cables, thereby improving the slot fill rate and having good heat dissipation performance; at the same time, by setting the shape of the first profiled coil and the second profiled coil to be complementary, the gap between the first profiled coil and the second profiled coil can be effectively reduced, and the slot fill rate can be further improved. The structure is compact and the volume can be reduced, which is conducive to improving the power density and torque density of the motor and can meet the needs of miniaturization of joint motors. Moreover, the first profiled coil and the second profiled coil can be wound with a single tooth, which can simplify the production process, the manufacturing process is simple, the coil winding is not limited by the slot, and a thicker winding cable can be used, which is suitable for low-voltage and high-current motors; it can also be wound using an automatic winding machine, which is conducive to improving the coil winding efficiency and higher motor production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 This is a schematic diagram of the structure of the motor stator of some embodiments of the present application.

[0034] Figure 2 This is a schematic structural diagram of an assembly of a motor stator according to some embodiments of the present application.

[0035] Figure 3 This is a schematic structural diagram of a single-tooth upper coated wire rack according to some embodiments of the present application.

[0036] Figure 4 This is a schematic structural diagram of the first stator unit in some embodiments of the present application.

[0037] Figure 5 This is a schematic structural diagram of the second stator unit in some embodiments of the present application.

[0038] Figure 6 This is a schematic diagram of the partial structure of the first pressed coil or the second pressed coil in some embodiments of the present application.

[0039] Figure 7 This is a schematic diagram of the structure of a single tooth in some embodiments of the present application.

[0040] Figure 8 This is a schematic diagram of the structure of a wiring board according to some embodiments of the present application.

[0041] Fig. 9 A schematic flow chart of a method for manufacturing a motor stator according to some embodiments of the present application.

[0042] Fig.10 This is a schematic structural diagram of a first winding unit according to some embodiments of the present application.

[0043] Fig.11This is a schematic structural diagram of a second winding unit in some embodiments of the present application.

[0044] Fig.12 This is a schematic diagram of performing a profiling process on a first winding monomer according to some embodiments of the present application.

[0045] Fig.13 This is a schematic diagram of performing a profiling process on a second winding monomer according to some embodiments of the present application.

[0046] Figure Number:

[0047] 100, motor stator; 10, assembly; 101, first stator monomer; 102, second stator monomer; 103, first winding monomer; 104, second winding monomer;

[0048] 1. stator core; 11. single tooth; 111. yoke; 112. tooth stem; 113. pole shoe; 114. boss; 115. groove;

[0049] 2. Wire rack; 21. Wire winding groove;

[0050] 3. First profiled coil; 31. First convex portion; 32. First concave portion; 33. First winding start end; 34. First winding end end; 30. First coil;

[0051] 4. second pressed coil; 41. second concave portion; 42. second convex portion; 43. second winding start end; 44. second winding end end; 40. second coil;

[0052] 5. Winding cable;

[0053] 6. Wiring board; 61. Wiring hole;

[0054] 200, first pressing mold; 201, first pressing mold core; 202, first pressing plate; 203, first pressing block;

[0055] 300, second pressing mold; 301, second pressing mold core; 302, second pressing plate; 303, second pressing block. DETAILED DESCRIPTION

[0056] In order to make the above-mentioned purposes, features and advantages of the present application more obvious and easy to understand, the specific implementation methods of the present application are described in detail below in conjunction with the accompanying drawings. In the following description, many specific details are set forth to facilitate a full understanding of the present application. However, the present application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar improvements without violating the connotation of the present application, so the present application is not limited by the specific embodiments disclosed below.

[0057] In the description of the present application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present application.

[0058] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In the description of this application, "plurality" means at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

[0059] In this application, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integrated connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements, unless otherwise clearly defined. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0060] In the present application, unless otherwise clearly specified and limited, a first feature being “above” or “below” a second feature may mean that the first and second features are in direct contact, or the first and second features are in indirect contact through an intermediate medium. Moreover, a first feature being “above”, “above”, and “above” a second feature may mean that the first feature is directly above or obliquely above the second feature, or simply means that the first feature is higher in level than the second feature. A first feature being “below”, “below”, and “below” a second feature may mean that the first feature is directly below or obliquely below the second feature, or simply means that the first feature is lower in level than the second feature.

[0061] It should be noted that when an element is referred to as being "fixed to" or "disposed on" another element, it may be directly on the other element or there may be a central element. An element is considered to be "connected to" another element, it may be directly connected to the other element or there may be a central element at the same time. The terms "vertical", "horizontal", "upper", "lower", "left", "right" and similar expressions used in this application are for illustrative purposes only and are not intended to be the only implementation method.

[0062] See also Figures 1 to 5 , Figure 1 shows a schematic diagram of the structure of the motor stator in some embodiments of the present application, Figure 2 The schematic diagram of the structure of the motor stator assembly in some embodiments of the present application is shown. Figure 3 The schematic diagram of the structure of the single-tooth upper coated wire rack in some embodiments of the present application is shown. Figure 4 shows a schematic structural diagram of a first stator monomer in some embodiments of the present application, Figure 5 A schematic diagram of the structure of the second stator monomer in some embodiments of the present application is shown. The motor stator 100 provided in the embodiment of the present application includes a stator core 1, a plurality of bobbins 2, a plurality of first corrugated coils 3 and a plurality of second corrugated coils 4. The stator core 1 includes a plurality of single teeth 11 that are sequentially spliced ​​along the circumference to form a full circle. Each single tooth 11 is covered with a bobbin 2, and the bobbin 2 is formed with a winding groove 21. The first corrugated coil 3 is wound in the winding groove 21 on one of any two adjacent single teeth 11, and the second corrugated coil 4 is wound in the winding groove 21 on the other single tooth 11. Among them, along the radial direction of the stator core 1, the first corrugated coil 3 has a first convex portion 31 and a first concave portion 32 arranged in sequence, and the second corrugated coil 4 has a second concave portion 41 and a second convex portion 42 arranged in sequence. The first convex portion 31 of the first corrugated coil 3 is arranged in the second concave portion 41 of the adjacent second corrugated coil 4, and the second convex portion 42 of the second corrugated coil 4 is arranged in the first concave portion 32 of the adjacent first corrugated coil 3.

[0063] The stator core 1 is assembled into a full circle by a plurality of single teeth 11, for example, the number of the single teeth 11 may be 16, 18, 20, etc. The single teeth 11 may include but are not limited to being made of silicon steel sheets.

[0064] The bobbin 2 wraps around the single tooth 11 and forms a winding groove 21 on the single tooth 11. The bobbin 2 is made of insulating material, for example, the material of the bobbin 2 may include but is not limited to plastic, rubber, etc. The bobbin 2 is located between the single tooth 11 and the first press-formed coil 3 to insulate the first press-formed coil 3 from the single tooth 11. Similarly, the bobbin 2 is located between the single tooth 11 and the second press-formed coil 4 to insulate the second press-formed coil 4 from the single tooth 11.

[0065] The profiled coil refers to a coil in which the winding cable 5 is wound on the single tooth 11 through the winding groove 21 and is profiled to be pressed into a set shape. After the coil is profiled, the gap between the winding cables 5 is greatly reduced, and the winding groove 21 is almost completely filled with the winding cables 5, with a high slot fill rate and good heat dissipation performance.

[0066] By adopting a set coil winding method, the coil winding height of a part of the first profiled coil 3 is greater than the coil winding height of another part, the part with a relatively larger coil winding height forms a first convex portion 31, and the part with a relatively smaller coil winding height forms a first concave portion 32, and the first convex portion 31 and the first concave portion 32 are arranged in sequence along the radial direction of the stator core 1, so that the first profiled coil 3 is in a stepped shape as a whole. The first profiled coil 3, the bobbin 2 and the single tooth 11 form a first stator monomer 101.

[0067] Similarly, by adopting a set coil winding method, the coil winding height of a part of the second profiled coil 4 is made smaller than the coil winding height of another part, the part with a relatively smaller coil winding height forms a second concave portion 41, and the part with a relatively larger coil winding height forms a second convex portion 42, and the second concave portion 41 and the second convex portion 42 are arranged in sequence along the radial direction of the stator core 1, so that the second profiled coil 4 is in a stepped shape as a whole. The second profiled coil 4, the bobbin 2 and the single tooth 11 form a second stator monomer 102.

[0068] Furthermore, the setting position of the first convex portion 31 of the first profiled coil 3 matches the setting position of the second concave portion 41 of the second profiled coil 4, so that the first convex portion 31 of the first profiled coil 3 can be set in the second concave portion 41 of the adjacent second profiled coil 4; the setting position of the first concave portion 32 of the first profiled coil 3 matches the setting position of the second convex portion 42 of the second profiled coil 4, so that the second convex portion 42 of the second profiled coil 4 can be set in the first concave portion 32 of the adjacent first profiled coil 3. In this way, the shapes of the first profiled coil 3 and the second profiled coil 4 obtained after the profile processing are complementary, and the first profiled coil 3 and the second profiled coil 4 are alternately spliced ​​into a full circle, which can fill the space in the winding slot 21 together, effectively reduce the interval space between the first profiled coil 3 and the second profiled coil 4, and can greatly improve the motor slot full rate, for example, the slot full rate can be made greater than 90%, and it will not affect the splicing of the single tooth 11 into a full circle. The first stator monomers 101 and the second stator monomers 102 are alternately spliced ​​into a full circle to form an assembled body 10 of the motor stator 100 .

[0069] The motor stator 100 of the embodiment of the present application uses a profiled coil to greatly reduce the gap between the winding cables 5, and the winding slot 21 is almost completely filled with the winding cables 5, thereby improving the slot fill rate and having good heat dissipation performance; at the same time, by setting the shape of the first profiled coil 3 and the second profiled coil 4 to be complementary, the gap between the first profiled coil 3 and the second profiled coil 4 can be effectively reduced, and the slot fill rate can be further improved. The structure is compact and the volume can be reduced, which is beneficial to improving the power density and torque density of the motor and can meet the needs of miniaturization of joint motors. Moreover, the first profiled coil 3 and the second profiled coil 4 can be wound with a single tooth 11, which can simplify the production process, the manufacturing process is simple, the coil winding is not limited by the notch, and a thicker winding cable 5 can be used, which is suitable for low-voltage and high-current motors; an automatic winding machine can also be used for winding, which is beneficial to improving the coil winding efficiency and higher motor production efficiency.

[0070] The motor stator 100 of the embodiment of the present application can be applied to the joint motor of a collaborative robot. Under the same power and torque, the miniaturized and compact design of the joint motor of the collaborative robot can be realized, the volume of the joint module can be reduced, which is conducive to the miniaturized design of the joint module, reduces the weight of the collaborative robot, and makes the collaborative robot have better flexibility and improves the flexible operation ability in narrow working space areas.

[0071] In some embodiments, see Figure 6 , Figure 6 A schematic diagram of the partial structure of the first corrugated coil 3 or the second corrugated coil 4 in some embodiments of the present application is shown, where two adjacent turns of the winding cable 5 of the first corrugated coil 3 are in surface contact, and two adjacent turns of the winding cable 5 of the second corrugated coil 4 are in surface contact.

[0072] After the coil is pressed, the winding cable 5 is squeezed and deformed, so that the point contact or line contact between two adjacent turns of the winding cable 5 changes to surface contact. In this way, the gap between the winding cables 5 is greatly reduced, making the structure of the first pressed coil 3 and the second pressed coil 4 more compact, with a higher slot fill rate, and can increase the heat transfer area, effectively improve the heat dissipation performance, which is conducive to improving the torque density and power density of the motor, and can meet the needs of miniaturization of joint motors.

[0073] In some embodiments, the winding cable 5 of the first profiled coil 3 is in surface contact with the single tooth 11 , and the winding cable 5 of the second profiled coil 4 is in surface contact with the single tooth 11 .

[0074] After the coil is pressed, the winding cable 5 is squeezed and deformed, so that the point contact or line contact between the winding cable 5 and the single tooth 11 changes to surface contact. In this way, the first pressed coil 3 and the second pressed coil 4 are both arranged close to the single tooth 11, the structure is more compact, and the slot fill rate is further improved. In addition, the outer ring of the stator core 1 can be in close contact with the external structure such as the robot arm shell, which is more conducive to dissipating heat, thereby having good heat dissipation performance, which is conducive to improving the torque density and power density of the motor, and can meet the needs of miniaturization of joint motors.

[0075] In some embodiments, after the coil is pressed, the winding cable 5 is squeezed and deformed, so that the gap between the first pressed coil 3 and the adjacent second pressed coil 4 can be further reduced, and even the winding cable 5 of the first pressed coil 3 and the winding cable 5 of the adjacent second pressed coil 4 can be at least partially in contact with each other. In this way, the structure of the motor stator 100 is more compact, the slot fill rate is further improved, and heat can be transferred between the adjacent first pressed coil 3 and the second pressed coil 4, so that it has better heat dissipation performance, which is conducive to improving the torque density and power density of the motor, and can meet the needs of miniaturization of joint motors.

[0076] In some embodiments, Figure 6 As shown, the cross-sectional shape of the winding cable 5 of the first profiled coil 3 and the second profiled coil 4 is a non-circular shape.

[0077] The winding cable 5 may include a conductor and an insulating layer covering the conductor. For example, the winding cable 5 may include but is not limited to an enameled wire. Before the coil is pressed, the cross-sectional shape of the winding cable 5 used for winding the coil is not limited. For example, the conductor may include but is not limited to round copper wire, flat copper wire, and hollow wire; the heat dissipation coefficient of copper is about 400W / mk, and the heat dissipation performance is good.

[0078] After the coil is pressed, the cross-sectional shape of the winding cable 5 is extruded into a non-circular shape such as a hexagon. In this way, it is beneficial to form surface contact between the two adjacent winding cables 5 of the first pressed coil 3, between the two adjacent winding cables 5 of the second pressed coil 4, between the winding cables 5 of the first pressed coil 3 and the single tooth 11, between the winding cables 5 of the second pressed coil 4 and the single tooth 11, and between the winding cables 5 of the first pressed coil 3 and the winding cables 5 of the adjacent second pressed coil 4, which can greatly reduce the gap in the winding slot 21, thereby greatly improving the slot fullness rate, and can increase the heat transfer area, effectively improve the heat dissipation performance, which is beneficial to improve the torque density and power density of the motor and meet the needs of miniaturization of the joint motor.

[0079] In some embodiments, see Figures 2 to 5 and Figure 7 , Figure 7The schematic diagram of the structure of a single tooth 11 in some embodiments of the present application is shown. The single tooth 11 includes a yoke 111 and a tooth portion. The yoke 111 is sequentially spliced ​​to form the outer ring of the stator core 1. The tooth portion includes a tooth stem 112 connected to the yoke 111 and a pole shoe 113 connected to the tooth stem 112. The pole shoes 113 are arranged at intervals to form the inner ring of the stator core 1. The winding slot 21 is located between the yoke 111 and the pole shoe 113. The first convex portion 31 and the second concave portion 41 are arranged close to the yoke 111, and the second convex portion 42 and the first concave portion 32 are arranged close to the pole shoe 113.

[0080] The winding groove 21 formed by the wire rack 2 is located between the yoke 111 and the pole shoe 113 of the single tooth 11, that is, the winding groove 21 is located on the tooth stem 112 of the single tooth 11, and the first pressed coil 3 and the second pressed coil 4 are respectively located on the tooth stem 112 of the corresponding single tooth 11. In some embodiments, the wire rack 2 and the single tooth 11 are integrally injection molded. By arranging the first protrusion 31 and the second recess 41 close to the yoke 111, and the second protrusion 42 and the first recess 32 close to the pole shoe 113, the shapes of the first pressed coil 3 and the second pressed coil 4 are complementary, and the splicing of the single tooth 11 into a full circle will not be affected.

[0081] In some embodiments, see Figures 2 to 5 and Figure 7 , each single tooth 11 is provided with a boss 114 and a groove 115 on opposite sides along the circumferential direction, respectively, and the boss 114 and the groove 115 can be plugged and matched, so that multiple single teeth 11 can be stably assembled into a full circle, which is conducive to ensuring the integrity of the motor structure and magnetic circuit. Among them, the specific shapes of the boss 114 and the groove 115 are not limited, for example, the groove 115 can include but is not limited to a semicircular groove, a waist-shaped groove, a dovetail groove, etc.

[0082] In some embodiments, see Figure 2 and Figure 4 The first pressed coil 3 has a first winding start end 33 and a first winding end 34, and the first winding start end 33 and the first winding end 34 are arranged close to the yoke 111 of the single tooth 11. Figure 2 and Figure 5 The second profiled coil 4 has a second winding start end 43 and a second winding end 44 , and the second winding start end 43 and the second winding end 44 are arranged close to the pole shoe 113 of the single tooth 11 .

[0083] The first winding start end 33 refers to the starting point when the winding cable 5 of the first profiled coil 3 is wound, and the first winding end 34 refers to the end point when the winding cable 5 of the first profiled coil 3 is wound. Similarly, the second winding start end 43 refers to the starting point when the winding cable 5 of the second profiled coil 4 is wound, and the second winding end 44 refers to the end point when the winding cable 5 of the second profiled coil 4 is wound.

[0084] By setting the winding starting points and ending points of the first press-formed coil 3 and the second press-formed coil 4 to be different, the winding space can be better utilized, and the winding position and quantity can be conveniently adjusted, which is beneficial to improving space utilization.

[0085] In some embodiments, see Figure 1 and Figure 8 , Figure 8 A schematic diagram of the structure of the terminal block 6 in some embodiments of the present application is shown, and the motor stator 100 also includes a terminal block 6, and a plurality of wiring holes 61 are opened on the terminal block 6, and the opening positions of the plurality of wiring holes 61 match the setting positions of the plurality of first winding starting ends 33, the plurality of first winding endings 34, the plurality of second winding starting ends 43 and the plurality of second winding endings 44; the plurality of first winding starting ends 33, the plurality of first winding endings 34, the plurality of second winding starting ends 43 and the plurality of second winding endings 44 are respectively penetrated through the corresponding wiring holes 61.

[0086] Along the axial direction of the stator core 1, the ends of the first profiled coil 3 and the second profiled coil 4 are connected to the terminal block 6. It can be understood that the first winding start 33 is the inlet end of the first profiled coil 3, and the first winding end 34 is the outlet end of the first profiled coil 3; the second winding start 43 is the inlet end of the second profiled coil 4, and the second winding end 44 is the outlet end of the second profiled coil 4. The first winding start 33 and the first winding end 34 of the first profiled coil 3 and the second winding start 43 and the second winding end 44 of the second profiled coil 4 can be connected and limited through the wiring hole 61 on the terminal block 6. For example, the wiring hole 61 can be a welding hole, and multiple first winding starts 33, multiple first winding ends 34, multiple second winding starts 43, and multiple second winding ends 44 are respectively welded and connected to the terminal block 6.

[0087] Since the wire diameter of the winding cable 5 of the low-voltage, high-current motor is usually thick and difficult to wind, the input and output wires of multiple first corrugated coils 3 and multiple second corrugated coils 4 are centrally fixed by using a terminal block 6, which can save space, make the structure more compact, and facilitate wiring operations, thereby meeting the needs of miniaturization of joint motors.

[0088] In some embodiments, the motor stator 100 can be potted as a whole using a potting glue. For example, the potting glue may include but is not limited to epoxy resin, etc. In this way, the heat dissipation capacity and operation stability of the motor can be greatly improved, which is conducive to improving the torque density and power density of the motor.

[0089] See also Fig. 9 , Fig. 9The flowchart of the manufacturing method of the motor stator 100 in some embodiments of the present application is shown. The embodiment of the present application also provides a manufacturing method of the motor stator 100, which is used to manufacture the motor stator 100 in the above embodiment. The manufacturing method of the motor stator 100 includes the following steps:

[0090] Step S100, winding a first coil 30 on the single tooth 11 of the wrapped bobbin 2 to obtain a first winding monomer 103; winding a second coil 40 on the single tooth 11 of the wrapped bobbin 2 to obtain a second winding monomer 104;

[0091] Step S200, using the first pressing mold 200 to press the first winding monomer 103 to obtain the first stator monomer 101; using the second pressing mold 300 to press the second winding monomer 104 to obtain the second stator monomer 102;

[0092] Step S300 , alternately splicing a plurality of first stator monomers 101 and a plurality of second stator monomers 102 along a circumference to form a full circle, thereby obtaining an assembled body 10 of the motor stator 100 .

[0093] The wire rack 2 and the single tooth 11 can be integrally injection molded. After the wire rack 2 is coated on the single tooth 11, it can be placed in an automatic winding machine for coil winding. The wire arrangement is neat and convenient, which can greatly improve the winding efficiency. In addition, when the single tooth 11 is used for winding, the wire diameter of the winding cable 5 is not affected by the slot size, which can be suitable for the coil winding of low-voltage and high-current motors. Two types of coils need to be wound, namely the first coil 30 and the second coil 40. Fig.10 As shown, the first coil 30 and the single tooth 11 covered with the bobbin 2 form a first winding monomer 103. Fig.11 As shown, the second coil 40 and the single tooth 11 covered with the bobbin 2 form a second winding monomer 104. The two coils can be wound at the same time, which can further improve the winding efficiency.

[0094] After the coil is wound, it needs to be pressed. Fig.12 As shown, the wound first winding monomer 103 is placed in the first pressing mold 200 for pressing treatment, so that the shape of the first coil 30 is deformed, and the cross-sectional shape of the winding cable 5 in the first coil 30 is also deformed, so that the first coil 30 is pressed into a first pressed coil 3. The first pressed coil 3 and the single tooth 11 covered with the wire frame 2 form the first stator monomer 101. Similarly, as Fig.13As shown, the wound second winding monomer 104 is placed in the second profiling mold 300 for profiling treatment, so that the shape of the second coil 40 is deformed, and the cross-sectional shape of the winding cable 5 in the second coil 40 is also deformed, so that the second coil 40 is pressed into a second profiling coil 4. The second profiling coil 4 and the single tooth 11 covered with the bobbin 2 form the second stator monomer 102. After the profiling treatment, the gap between the winding cable 5 of the first profiling coil 3 and the second profiling coil 4 is greatly reduced, and the winding slot 21 is almost completely filled with the winding cable 5, which effectively improves the slot fill rate; and the shapes of the first profiling coil 3 and the second profiling coil 4 are complementary. The first winding monomer 103 and the second winding monomer 104 can be profiling treated at the same time, which can further improve the processing efficiency.

[0095] The first stator monomer 101 and the second stator monomer 102 after pressing are alternately spliced ​​into a full circle along the circumference, thereby forming an assembled body 10 of the motor stator 100. Since the shapes of the first pressed coil 3 and the second pressed coil 4 are complementary, the gap between the first pressed coil 3 and the second pressed coil 4 can be effectively reduced, further improving the slot fill rate and making the structure more compact.

[0096] In some embodiments, the manufacturing method of the motor stator 100 may further include step S400: connecting the terminal block 6 to the assembly body 10, so that the first winding start end 33 and the first winding end 34 of the first pressed coil 3 and the second winding start end 43 and the second winding end 44 of the second pressed coil 4 are respectively inserted into the corresponding wiring holes 61 on the terminal block 6, thereby obtaining the motor stator 100.

[0097] In some embodiments, the method for manufacturing the motor stator 100 may further include step S500: potting the motor stator 100 into a whole using potting glue; the potting glue may be epoxy resin.

[0098] The manufacturing method of the motor stator 100 of the embodiment of the present application adopts a single tooth 11 to wind the coil, which effectively simplifies the production process. The manufacturing process is simple, the coil winding is not limited by the slot, and a thicker winding cable 5 can be used. It is suitable for low-voltage and high-current motors. At the same time, the use of profiling treatment can greatly reduce the gap between the winding cables 5 and improve the slot fill rate, which is beneficial to improve the power density and torque density of the motor, can meet the needs of miniaturization of joint motors, and can effectively improve the coil winding efficiency and profiling treatment efficiency, thereby improving the motor production efficiency.

[0099] In some embodiments, the first coil 30 is wound on the single tooth 11 wrapped with the bobbin 2 to obtain the first winding monomer 103, which specifically includes the following steps:

[0100] Step S110, determining the wire diameter and number of windings of the winding cable 5 of the first coil 30 according to the motor power;

[0101] Step S120, on the single tooth 11 wrapped with the wire frame 2, with the yoke 111 close to the single tooth 11 as the winding starting point and winding end point, the winding cable 5 is sequentially wound in the winding groove 21 along the extension direction of the tooth stem 112 of the single tooth 11 and wound from the inside to the outside in multiple layers to form a first coil 30, and the number of winding layers of the first coil 30 close to the yoke 111 is greater than the number of winding layers close to the pole shoe 113, thereby obtaining a first winding monomer 103.

[0102] According to the winding space theory, the cross-sectional area of ​​the first coil 30 is ≤ the cross-sectional area of ​​the winding slot 21. Fig.10 As shown, the cross-sectional area of ​​the first coil 30 is equal to the sum of the cross-sectional areas of all the winding cables 5 on the cross-sectional area, wherein the cross-sectional area can be calculated according to the circumscribed circle of the cross-sectional area of ​​the winding cables 5. At the same time, the motor power has a corresponding relationship with the wire diameter and the number of windings of the winding cables 5 in the coil. Therefore, based on the winding space theory, the wire diameter and the number of windings of the winding cables 5 of the first coil 30 can be determined according to the motor power.

[0103] Then, according to the shape of the first pressed coil 3, the winding method of the first coil 30 can be determined, that is, the winding starting point and winding end point of the first coil 30 are close to the yoke 111 of the single tooth 11, and the number of winding layers of the first coil 30 close to the yoke 111 is greater than the number of winding layers close to the pole shoe 113, so that the coil winding height of a part of the first coil 30 close to the yoke 111 is greater than the coil winding height of another part close to the pole shoe 113. It should be noted that since the winding of the single tooth 11 is not restricted by the notch, the first coil 30 can be higher than the winding slot 21, as long as the cross-sectional area of ​​the first pressed coil 3 after pressing meets the theoretical requirements of the winding space.

[0104] After the winding method is determined, an automatic winding machine can be used for winding, thereby obtaining the first winding monomer 103, which makes the wiring arrangement neat and convenient, and greatly improves the winding efficiency.

[0105] In some embodiments, the second coil 40 is wound on the single tooth 11 wrapped with the bobbin 2 to obtain the second winding monomer 104, which specifically includes the following steps:

[0106] Step S130, determining the wire diameter and number of windings of the winding cable 5 of the second coil 40 according to the motor power;

[0107] Step S140, on the single tooth 11 wrapped with the wire frame 2, with the pole shoe 113 close to the single tooth 11 as the winding starting point and winding end point, the winding cable 5 is sequentially wound in the winding groove 21 along the extension direction of the tooth stem 112 of the single tooth 11 and wound multiple layers from the inside to the outside to form a second coil 40, and the number of winding layers of the second coil 40 close to the pole shoe 113 is greater than the number of winding layers close to the yoke 111, thereby obtaining a second winding monomer 104.

[0108] Similarly, if Fig.11 As shown, the cross-sectional area of ​​the second coil 40 is equal to the sum of the cross-sectional areas of all the winding cables 5 on the cross section. The wire diameter and the number of winding turns of the winding cable 5 of the second coil 40 can be determined based on the winding space theory and the motor power. Then, according to the shape of the second profiled coil 4, the winding method of the second coil 40 can be determined, that is, the winding starting point and the winding end point of the second coil 40 are close to the pole shoe 113 of the single tooth 11, and the number of winding layers of the second coil 40 close to the pole shoe 113 is greater than the number of winding layers close to the yoke 111, so that the coil winding height of a part of the second coil 40 close to the yoke 111 is less than the coil winding height of another part close to the pole shoe 113. The second coil 40 can also be higher than the winding slot 21. After determining the winding method, an automatic winding machine can be used for winding, thereby obtaining a second winding monomer 104, which is neat and convenient to arrange the wires, and greatly improves the winding efficiency.

[0109] In some embodiments, a first profiling mold 200 is used to perform profiling on the first winding monomer 103 to obtain the first stator monomer 101, which specifically includes the following steps:

[0110] Step S210, fixing the first winding unit 103 in the first pressing mold 200;

[0111] Step S220 , driving the first pressing mold 200 to press the first winding monomer 103 , and during the pressing process, simultaneously passing a high-frequency current into the winding cable 5 of the first winding monomer 103 for preheating, so as to press the first coil 30 into a first pressed coil 3 , thereby obtaining the first stator monomer 101 .

[0112] like Fig.12 As shown, the first pressing mold 200 may include a first pressing mold core 201, a first pressing plate 202 and two first pressing blocks 203. The wound first winding monomer 103 is fixed in the groove of the first pressing mold core 201, the first pressing plate 202 is used to press the yoke 111 of the outer edge of the single tooth 11 to prevent movement, and the two sides are pressed by two first pressing blocks 203 to form a desired shape. For example, a punching machine can be used to drive the first pressing mold 200 for pressing.

[0113] During the forming process, a high-frequency current is passed through the winding cable 5 of the first winding monomer 103 for preheating, so that the winding cable 5 is more easily deformed. The preheating temperature and preheating time can be controlled according to the amount of deformation required, and closely cooperate with the forming process to ensure that the winding cable 5 can be pressed into the required shape without damaging the enameled wire film, thereby ensuring the insulation performance.

[0114] By energizing for preheating during the profiling process, the first coil 30 is facilitated to be profiled, ensuring the profiling effect while not damaging the insulation performance, which is beneficial to improving the torque density and power density of the motor and meeting the needs of miniaturization of the joint motor.

[0115] It should be noted that, in other embodiments, the first winding monomer 103 may also be directly stamped, and this application does not impose any limitation on this.

[0116] In some embodiments, the second stator unit 102 is obtained by performing a profiling process on the second winding unit 104 using the second profiling mold 300, which specifically includes the following steps:

[0117] Step S230, fixing the second winding unit 104 in the second pressing mold 300;

[0118] Step S240 , driving the second pressing mold 300 to press the second winding monomer 104 , and during the pressing process, simultaneously passing a high-frequency current into the winding cable 5 of the second winding monomer 104 for preheating, so as to press the second coil 40 into a second pressed coil 4 , thereby obtaining a second stator monomer 102 .

[0119] like Fig.13 As shown, the second pressing mold 300 may include a second pressing mold core 301, a second pressing plate 302 and two second pressing blocks 303. The wound second winding monomer 104 is fixed in the groove of the second pressing mold core 301, the second pressing plate 302 is used to press the yoke 111 of the outer edge of the single tooth 11 to prevent movement, and the two sides are pressed by two second pressing blocks 303 to form a desired shape. For example, a punching machine can be used to drive the second pressing mold 300 for pressing.

[0120] During the forming process, a high-frequency current is passed through the winding cable 5 of the second winding monomer 104 for preheating, so that the winding cable 5 is more easily deformed. The preheating temperature and preheating time can be controlled according to the amount of deformation required, and closely cooperate with the forming process to ensure that the winding cable 5 can be pressed into the required shape without damaging the enameled wire film, thereby ensuring the insulation performance.

[0121] By energizing for preheating during the profiling process, the second coil 40 is facilitated to be profiled, ensuring the profiling effect while not damaging the insulation performance, which is beneficial to improving the torque density and power density of the motor and meeting the needs of miniaturization of the joint motor.

[0122] It should be noted that, in other embodiments, the first winding monomer 103 and the second winding monomer 104 may also be directly stamped and formed, and this application does not impose any limitation on this.

[0123] Based on the same inventive concept, an embodiment of the present application further provides a motor, which includes the motor stator 100 provided in any of the above embodiments.

[0124] For example, the motor can be a joint motor for a robot, the robot can be a collaborative robot, and the motor can be used in the joint module of the robot.

[0125] Since the motor has the same beneficial effects as the motor stator 100 of the above embodiment, they are not described in detail here.

[0126] The technical features of the above-described embodiments may be arbitrarily combined. To make the description concise, not all possible combinations of the technical features in the above-described embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0127] The above-described embodiments only express several implementation methods of the present application, and the descriptions thereof are relatively specific and detailed, but they cannot be construed as limiting the scope of the patent application. It should be pointed out that, for a person of ordinary skill in the art, several variations and improvements can be made without departing from the concept of the present application, and these all belong to the protection scope of the present application. Therefore, the protection scope of the patent application shall be subject to the attached claims.

Claims

1. A motor stator, characterized in that: include: The stator core comprises a plurality of single teeth which are sequentially spliced ​​along the circumference to form a full circle; A plurality of wire racks, each of the single teeth is covered with the wire rack, and the wire rack is formed with a winding groove; A plurality of first profiled coils and a plurality of second profiled coils, wherein the first profiled coil is wound in the winding groove on one of any two adjacent single teeth, and the second profiled coil is wound in the winding groove on the other of the two adjacent single teeth; Among them, along the radial direction of the stator core, the first corrugated coil has a first convex portion and a first concave portion arranged in sequence, and the second corrugated coil has a second concave portion and a second convex portion arranged in sequence, the first convex portion of the first corrugated coil is arranged in the second concave portion of the adjacent second corrugated coil, and the second convex portion of the second corrugated coil is arranged in the first concave portion of the adjacent first corrugated coil.

2. The motor stator according to claim 1, characterized in that: The two adjacent winding wires of the first profiled coil are in surface contact with each other, and the two adjacent winding wires of the second profiled coil are in surface contact with each other; And / or, the winding cable of the first profiled coil is in surface contact with the single tooth, and the winding cable of the second profiled coil is in surface contact with the single tooth.

3. The motor stator according to claim 1, characterized in that: The cross-sectional shape of the winding cables of the first and second profiled coils is non-circular.

4. The motor stator according to any one of claims 1 to 3, characterized in that: The single tooth includes a yoke and a tooth, the yoke is spliced ​​in sequence to form the outer ring of the stator core, the tooth includes a tooth stem connected to the yoke and a pole shoe connected to the tooth stem, and the pole shoes are arranged at intervals to form the inner ring of the stator core; the winding groove is located between the yoke and the pole shoe; the first protrusion and the second recess are arranged close to the yoke, and the second protrusion and the first recess are arranged close to the pole shoe.

5. The motor stator according to claim 4, characterized in that: The first pressed coil has a first winding start and a first winding end, and the first winding start and the first winding end are arranged close to the yoke of the single tooth; the second pressed coil has a second winding start and a second winding end, and the second winding start and the second winding end are arranged close to the pole shoe of the single tooth.

6. The motor stator according to claim 5, characterized in that: The motor stator further comprises a wiring board, on which a plurality of wiring holes are opened, and the opening positions of the plurality of wiring holes match the setting positions of the plurality of first winding starting ends, the plurality of first winding ending ends, the plurality of second winding starting ends and the plurality of second winding ending ends; A plurality of the first winding starting ends, a plurality of the first winding ending ends, a plurality of the second winding starting ends and a plurality of the second winding ending ends are respectively inserted into the corresponding wiring holes.

7. A method for manufacturing a motor stator, characterized in that: Used to manufacture the motor stator according to any one of claims 1 to 6, the manufacturing method of the motor stator comprising: Winding a first coil on a single tooth of the coated bobbin to obtain a first winding monomer; winding a second coil on a single tooth of the coated bobbin to obtain a second winding monomer; Using a first pressing mold to press the first winding monomer to obtain a first stator monomer; using a second pressing mold to press the second winding monomer to obtain a second stator monomer; A plurality of first stator monomers and a plurality of second stator monomers are alternately spliced ​​along the circumference to form a full circle, thereby obtaining an assembled body of the motor stator.

8. The method for manufacturing a motor stator according to claim 7, characterized in that: The step of winding the first coil on the single tooth of the coated bobbin to obtain the first winding monomer comprises: Determine the wire diameter and number of windings of the winding cable of the first coil according to the motor power; On the single tooth wrapped with the wire frame, the yoke close to the single tooth is used as the winding starting point and winding end point, and the winding cable is sequentially wound in the winding groove along the extension direction of the tooth stem of the single tooth and wound multiple layers from the inside to the outside to form a first coil, and the number of winding layers close to the yoke of the first coil is greater than the number of winding layers close to the pole shoe, thereby obtaining a first winding monomer; The step of winding a second coil on a single tooth of the coated bobbin to obtain a second winding monomer comprises: Determine the wire diameter and number of windings of the winding cable of the second coil according to the motor power; On a single tooth wrapped with a wire frame, the pole shoe close to the single tooth is used as the winding starting point and winding end point, and the winding cable is wound in the winding groove in sequence along the extension direction of the tooth stem of the single tooth and wound in multiple layers from the inside to the outside to form a second coil, and the number of winding layers of the second coil close to the pole shoe is greater than the number of winding layers close to the yoke, thereby obtaining a second winding monomer.

9. The method for manufacturing a motor stator according to claim 7, characterized in that: The method of using a first profiling die to perform profiling on the first winding monomer to obtain a first stator monomer includes: Fixing the first winding monomer in the first pressing mold; The first forming mold is driven to form a first winding monomer, and during the forming process, a high-frequency current is simultaneously passed through the winding cable of the first winding monomer to preheat the winding cable, so as to form the first coil into a first forming coil, thereby obtaining a first stator monomer; The method of using a second profiling die to perform profiling on the second winding monomer to obtain a second stator monomer comprises: Fixing the second winding monomer in the second pressing mold; The second pressing mold is driven to press the second winding monomer, and during the pressing process, a high-frequency current is simultaneously passed through the winding cable of the second winding monomer for preheating, so as to press the second coil into a second pressed coil, thereby obtaining a second stator monomer.

10. A motor, characterized in that: The invention comprises a motor stator as claimed in any one of claims 1 to 6.

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