Stator structure with separated tooth yoke part and processing method thereof

Abstract

The invention discloses a stator structure with separated tooth and yoke parts and a processing method thereof, the stator structure comprises a stator core and a stator winding, the stator core comprises a stator outer core and a stator inner core, a stator tooth part is formed on the stator inner core, a stator yoke part is formed on the stator outer core, and the stator winding is arranged on the stator outer core. Therefore, the stator tooth part and the stator yoke part of the stator core are separated. The processing method comprises a stator outer iron core processing method, a stator inner iron core processing method and a stator winding assembling method. According to the invention, a special stator structure form with separated tooth and yoke parts is adopted, so that the problem of a W-pin winding wire embedding process is solved; magnetic field distribution can be optimized through different notch structure forms, and the vibration and noise problems caused by electromagnetic force generated in the operation process of the motor to the new energy automobile are reduced; the sectional area of a copper wire is increased through different groove type design, and the motor operation efficiency is improved; and through a rotary bonding mode, the material cost is reduced, and the loss caused by welding and riveting is reduced.

Description

Technical Field

[0001] The invention relates to the technical field of motors, and in particular to a stator structure with a separated tooth yoke part and a processing method thereof. Background Art

[0002] The motor is mainly composed of a stator structure and a rotor structure, and the design of the stator structure has a direct impact on the performance of the motor. The stator structure mainly includes a stator core and a stator winding. The stator core is part of the motor magnetic circuit. The inner circle of the stator core is punched with evenly distributed stator slots to embed the stator winding. The solid part between two adjacent slots in the stator core forms the stator teeth. These stator teeth are the path through which the air gap flux passes. Since the stator core is made of magnetic conductive material, the magnetic permeability of the stator teeth is very high, while the magnetic permeability of the material of the stator slot is very low, so the magnetic flux is mainly conducted through the stator teeth. The design of the stator teeth has an important influence on the magnetic flux distribution and performance of the motor. The area formed between the bottom of the stator slot and the outer circle in the stator core is the stator yoke, which is the part that connects all the stator teeth. The stator yoke acts as a bridge in the motor to conduct magnetic flux and is also a supporting structure for the stator teeth. The stator winding is the circuit part of the motor. It is embedded in the stator slots in sequence according to a certain spatial angle and is insulated from the stator core.

[0003] With the continuous improvement of new energy vehicle technology, electric drive systems are increasingly developing towards high power density, high efficiency, and low cost. Therefore, it is particularly important to improve motor efficiency and reduce motor costs (production and manufacturing costs). In order to meet the performance requirements of new energy vehicles for motors, flat wire motors are increasingly used as drive motors in new energy vehicles. Flat wire motors are a type of winding design in motors, characterized by the use of flat wires instead of traditional round wires in the stator winding. The flat wires of flat wire motors can be filled more tightly in the stator slots, improving the utilization of the slots, so that more copper wires can be accommodated in the same volume, increasing the power density of the motor. At the same time, since flat wire motors can reduce the size and weight of motors at the same power, this helps to achieve miniaturization and lightweighting of motors, which is very attractive for application scenarios such as new energy vehicles that have strict requirements on space and weight. Therefore, flat wire motors are often used in drive motors for new energy vehicles, as well as other occasions that require high power density and high efficiency, such as industrial automation, household appliances, and aerospace.

[0004] In the prior art, there are many solutions for the stator winding of flat wire motors, such as Hair-pin, I-pin, X-pin, and W-pin. Among them, W-pin has outstanding advantages in efficiency, power density, cost, and other aspects. However, W-pin is the most complicated of the above winding types in the stator manufacturing process. Currently, most of the industry adopts the form of open slots and wire embedding in the slots. When the existing W-pin motors with open slots and wire embedding in the slots are used in new energy vehicles, the electromagnetic force generated during operation will still cause greater vibration and noise problems to new energy vehicles. Therefore, how to design a more reasonable stator structure to simultaneously meet the simple and easy-to-implement W-pin production process, improve the motor operation efficiency, reduce the cost of motor raw materials, and reduce the impact of vibration and noise has also become a technical problem that needs to be solved urgently. Summary of the invention

[0005] In view of the above-mentioned deficiencies in the prior art, the technical problem to be solved by the present invention is: how to provide a stator structure with a separated tooth yoke part and a processing method thereof that can simultaneously meet the requirements of a simple and easy-to-implement W-pin production process, improve the operating efficiency of the motor, reduce the cost of motor raw materials, and reduce the impact of vibration and noise.

[0006] In order to solve the above technical problems, the present invention adopts the following technical solutions: A stator structure with a separated tooth yoke portion comprises a stator core and a stator winding, wherein the stator core comprises a stator outer core and a stator inner core, a stator tooth portion is formed on the stator inner core, and a stator yoke portion is formed on the stator outer core, so that the stator tooth portion and the stator yoke portion of the stator core are separated.

[0007] Preferably, a first matching structure is provided on the inner circle of the stator outer core, and a second matching structure adapted to the first matching structure is provided on the outer circle of the stator inner core, so that a complete stator core is formed through the mutual cooperation of the first matching structure and the second matching structure.

[0008] Preferably, a stator slot assembly is provided on the stator inner core, and the stator slot assembly includes a plurality of stator slots with fully enclosed slot openings.

[0009] Preferably, a stator slot assembly is provided on the stator inner core, and the stator slot assembly includes a plurality of first stator slots and a plurality of second stator slots, the first stator slots have fully enclosed slot openings, and the second stator slots have incompletely enclosed slot openings.

[0010] Preferably, a plurality of the second stator slots are arranged in a set manner in the circumferential direction, and the second stator slots are semi-closed slots, symmetrical slots or fully open slots.

[0011] Preferably, the stator inner core comprises a plurality of inner iron core sheets arranged along the axial direction, and the plurality of inner iron core sheets are staggered in the axial direction.

[0012] A method for processing a stator structure with a separated tooth yoke part as described above comprises a method for processing a stator outer core, a method for processing a stator inner core and a method for assembling a stator winding.

[0013] Preferably, the processing method of the stator outer core is: the stator outer core is formed by a whole circle stamping and then a single piece stacking, a single piece chain structure winding and stacking, a petal stamping and then a rotation bonding, or a petal splicing and assembly.

[0014] Preferably, the processing method of the stator inner iron core is: the stator inner iron core is formed by a plurality of inner iron core sheets stacked in sequence along the axial direction, the inner iron core sheets are formed by a plurality of single-piece stator structures rotated and spliced ​​in sequence along the circumferential direction, and two adjacent single-piece stator structures are connected by self-adhesion or dispensing, the single-piece stator structure has N stator teeth and M stator slots, and N and M are both positive integers.

[0015] Preferably, the stator winding is assembled by embedding the stator winding into the stator slot from the outside of the stator inner core, and then assembling the stator outer core and the stator inner core.

[0016] Compared with the prior art, the present invention has the following advantages: 1. The present invention adopts the structural design of the stator outer core and the stator inner core, forms a stator tooth portion on the stator inner core, and forms a stator yoke portion on the stator outer core, thereby forming a special stator structure with separated tooth yoke portions of the present invention, solving the problem of W-pin winding embedding process; different notch structures can optimize the magnetic field distribution and reduce the vibration and noise problems caused by the electromagnetic force generated during the operation of the motor to new energy vehicles; different slot designs can increase the cross-sectional area of ​​the copper wire and improve the motor operation efficiency; and the rotary bonding form can reduce the material cost and the loss caused by welding and riveting.

[0017] 2. In the present invention, the outer core of the stator is made of high-quality soft magnetic materials such as non-oriented silicon steel sheets, amorphous alloys, and SMC, which have excellent magnetic conductivity. At the same time, the single-piece stator structure that constitutes the inner core of the stator is formed by processing non-oriented or oriented silicon steel sheets. The combination of non-oriented silicon steel sheets and oriented silicon steel sheets can give full play to their respective advantages and improve the efficiency of the motor.

[0018] 3. The forming methods of the stator outer core in the present invention include single-piece stacking after full-circle stamping, single-piece chain-like structure winding and stacking, split-piece stamping and rotation bonding, or split-piece splicing and assembly, etc., to form a complete stator outer core. The stator inner core is made of multiple single-piece stator structures that are rotated and stacked into inner iron core sheets one by one by self-adhesion or dispensing. With the maturity of self-adhesive core technology, the use of rotary splicing can reduce the impact of copper plate differences on laminations, reduce the cost of motor raw materials, reduce losses caused by connection methods such as rivet structures and welding structures, and improve motor operating efficiency.

[0019] 4. In the present invention, the inner and outer surfaces of the stator outer core are designed with a first matching structure according to specific needs. The first matching structure can be an irregular groove or protrusion structure. This structure on the inner surface of the stator outer core is mainly used to closely match with the second matching structure of the stator inner core to combine into a complete stator core, thereby providing an efficient conduction path for the magnetic field. The size and shape of the first matching structure and the second matching structure can be precisely designed according to the performance requirements of the motor, thereby achieving the purpose of optimizing the magnetic field distribution.

[0020] 5. The special structure on the outer surface of the stator outer core is mainly used to cooperate with the motor casing to fix the stator structure, or to form oil channels to facilitate the heat dissipation of the motor. Similarly, its size and shape are also designed according to the motor performance requirements to achieve the purpose of optimizing the stability of the stator structure.

[0021] 6. The monolithic stator structure is directly processed from non-oriented or oriented silicon steel sheets, or pre-processed into an initial monolithic structure, and then formed into a monolithic stator structure through later shaping. The slot position of the monolithic stator structure is in a closed state. The tooth structure of the monolithic stator structure has N teeth (N is a positive integer), and the shape of its slot position can be flexibly adjusted to any shape according to the design requirements, so as to optimize the magnetic circuit structure. Moreover, the slot position at the splicing of two adjacent monolithic stator structures can change the size and shape of the splicing position according to actual needs. Through rotational splicing, a variety of slot combinations such as fully closed slots, evenly spaced semi-closed slots in the circumferential direction, unevenly spaced semi-closed slots in the circumferential direction, evenly spaced symmetrical slots in the circumferential direction, and evenly spaced fully open slots in the circumferential direction are finally formed in the circumferential direction. It can also be formed in the axial direction through the staggered setting of the inner iron sheet in the axial direction. A variety of forms such as a straight spiral slot, a Z-shaped spiral slot, a V-shaped spiral slot, and a multi-layer overlapping overall staggered slot are formed in the axial direction to further optimize the magnetic circuit structure. Different stator slot structures can provide more space for the motor windings while ensuring the motor slot full rate, increase the winding cross-sectional area to reduce the winding heat generation, or reduce resistance to improve efficiency.

[0022] 7. As a key component of the motor, the stator winding is composed of conductive materials and insulating materials. Its main function is to generate a magnetic field by passing current to drive the motor. The stator winding of this solution covers round wire winding, flat wire winding (Hair-pin, I-pin, X-pin, etc.) in terms of structural form, especially the continuous wave winding (W-pin) structure. In addition, the number of turns and wire diameter of the winding can be reasonably designed according to the specific parameters of the motor such as power and voltage to ensure that the motor can achieve optimal performance under different working conditions. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Attached Figure 1 It is a structural schematic diagram of a stator structure with a separated tooth yoke part according to the present invention; Attached Figure 2 It is a structural schematic diagram of the first matching structure on the stator outer core in the stator structure with the tooth yoke part separated according to the present invention; Attached Figure 3 It is a structural schematic diagram of the second matching structure on the inner iron core of the stator in the stator structure with the tooth yoke part separated according to the present invention; Attached Figure 4 It is a schematic structural diagram of stator slots at the joints of different structures in the stator inner core in the stator structure with separated tooth yoke parts of the present invention; Attached Figure 5 It is a schematic structural diagram of different axial misalignment conditions of the inner iron core sheets in the stator inner iron core in the stator structure with the tooth yoke part separated according to the present invention; Attached Figure 6 Schematic diagram of different forming methods of the stator outer core in the stator structure with separated tooth yoke parts of the present invention; Attached Figure 7 It is a schematic diagram of a forming method of a stator inner core in a stator structure with a separated tooth yoke part according to the present invention; Attached Figure 8 It is a schematic diagram of the structure of different stator slots in the stator structure with separated tooth yoke parts of the present invention; Attached Fig. 9 It is a structural schematic diagram of different notch shapes of a single-piece stator structure in a stator structure with a separated tooth yoke portion of the present invention.

[0024] Explanation of the accompanying drawings: stator outer core 1 , first matching structure 101 , stator inner core 2 , second matching structure 201 , single-piece stator structure 202 , initial single-piece structure 203 , stator slot 204 , stator winding 3 . DETAILED DESCRIPTION

[0025] In order to make the purpose, technical scheme and advantages of the embodiments of the present invention clearer, the technical scheme in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. The components of the embodiments of the present invention generally described and shown in the drawings here can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present invention provided in the drawings is not intended to limit the scope of the claimed invention, but merely represents selected embodiments of the present invention. Based on the embodiments in the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work belong to the scope of protection of the present invention.

[0026] The motor is mainly composed of a stator and a rotor, wherein the stator generally includes a stator core and a housing. The outer surface of the stator core is matched and fixedly connected with the housing. Stator slots are provided on the stator core, and stator windings are embedded in the stator slots. Among them, the solid part between two adjacent stator slots in the stator core is the stator tooth. The stator tooth is the path through which the air gap magnetic flux passes. The magnetic permeability of the stator tooth is very high, while the magnetic permeability of the air in the stator slot is very low, so the magnetic flux is mainly conducted through the stator teeth. The area formed between the bottom of the stator slot and the outer circle in the stator core is the stator yoke, which is the part that connects all the stator teeth. The stator yoke acts as a bridge in the motor to conduct magnetic flux, and is also the supporting structure of the stator teeth. The direction of the magnetic field transmitted by the stator teeth is repeatedly transmitted along the radial direction, which conforms to the use characteristics of oriented silicon steel sheets. The direction of the magnetic field transmitted by the stator yoke is universally axial and radial, which conforms to the use characteristics of soft magnetic materials such as non-oriented silicon steel sheets. Therefore, the design and material application of the stator teeth and stator yoke have an important impact on the distribution and performance of the motor magnetic flux. At the same time, the existing motor stator structure generally adopts the same material stamping form, which is extremely unfriendly to the W-pin winding embedding process. Most of them adopt the open slot form. Therefore, the electromagnetic force generated brings greater vibration and noise problems to new energy vehicles.

[0027] Based on the W-pin winding embedding process problem, the electromagnetic force generated by the existing open slot stator structure causes vibration and noise problems to new energy vehicles, etc., in this specific embodiment, a stator structure with a separated tooth yoke is provided, as shown in the attached Figure 1 As shown, the stator structure includes a stator core and a stator winding 3, wherein the stator core includes a stator outer core 1 and a stator inner core 2, wherein stator slots are opened on the stator inner core 2, and the stator winding 3 is embedded in the stator slots. The solid parts of two adjacent stator slots on the stator inner core 2 form a stator tooth portion, and a stator yoke portion is formed on the stator outer core, so that the stator tooth portion and the stator yoke portion of the stator core are separated.

[0028] The present invention adopts the structural design of the stator outer core 1 and the stator inner core 2, forms a stator tooth portion on the stator inner core 2, and forms a stator yoke portion on the stator outer core 1, thereby forming a special stator structure with separated tooth and yoke portions. The structure with separated tooth and yoke portions can optimize the magnetic field distribution and reduce the vibration and noise problems caused to new energy vehicles by the electromagnetic force generated during the operation of the motor.

[0029] In this specific embodiment, as shown in the attached Figure 2 As shown, a first matching structure 101 is provided on the inner circle of the stator outer core 1, and a second matching structure 201 adapted to the first matching structure 101 is provided on the outer circle of the stator inner core 2, so that a complete stator core is formed by the mutual cooperation of the first matching structure 101 and the second matching structure 201. The first matching structure 101 can be a full circle structure, an irregular groove or a convex structure, and its specific shape includes but is not limited to a semicircular structure (such as the attached Figure 2 101-a), dovetail shape (as shown in the attached Figure 2 101-b), square (as shown in the attached Figure 2 101-c in the figure), and any regular or irregular shape, the main function of the first matching structure 101 on the stator outer core 1 is to cooperate with the second matching structure 201 at the root of the stator inner core 2 to form a complete motor stator core and provide a magnetic field conduction path. Its size and shape can be precisely designed according to the motor performance requirements to optimize the magnetic field distribution. For example, when the first matching structure 101 is a semicircular groove structure (as shown in the attached Figure 2 101-a in the figure), the second matching structure 201 is also a semicircular convex structure adapted thereto (as shown in the attached figure). Figure 2 201-a in FIG); when the first matching structure 101 is a dovetail groove structure (as shown in FIG. Figure 2 101-b in the figure), the second matching structure 201 is also a dovetail-shaped protrusion structure adapted thereto (as shown in the attached figure). Figure 3 201-b in the figure), and when a dovetail groove structure is adopted, arc fillets are provided at the corners to avoid stress concentration problems; when the first matching structure 101 is a square groove structure (as shown in the figure), Figure 2 101-c in the figure), the second matching structure 201 is also a square protruding structure adapted thereto (as shown in the attached figure). Figure 3 As shown in 201-c in the figure), when a square groove structure is adopted, arc fillets are provided at the corners to avoid stress concentration problems.

[0030] In this specific embodiment, a stator slot assembly is provided on the stator inner core 2, and the stator slot assembly includes a plurality of stator slots with fully enclosed slots. In this case, all stator slots are enclosed slots. Figure 4As shown in (a) in the figure. In addition to adopting stator slots with fully enclosed slots, the stator slot assembly can also adopt a structural form that combines fully enclosed slots and incompletely enclosed slots. In this case, the stator slots with fully enclosed slots are defined as first stator slots, and the stator slots with incompletely enclosed slots are defined as second stator slots. The number and distribution positions of the first stator slots and the second stator slots in the circumferential direction are set as required. For example, it can be designed that a first stator slot with a fully enclosed slot and a second stator slot with an incompletely enclosed slot are arranged in sequence in the circumferential direction, or two consecutive first stator slots with fully enclosed slots and a second stator slot with an incompletely enclosed slot are arranged in sequence in the circumferential direction. There are many setting methods, which are not listed one by one in this specific embodiment, and can be reasonably set as required in the actual design process.

[0031] Specifically, when the stator slot assembly adopts a structure in which a fully enclosed first stator slot and an incompletely enclosed second stator slot are combined, the slot opening of the second stator slot can also be designed in a different structure. For example, the second stator slot can adopt a semi-enclosed slot structure (such as the attached Figure 4 b and c in the figure), symmetrical notch structure (as shown in the attached Figure 4 d in the figure), full slot structure (as shown in the attached Figure 4 The specific structural form of the second stator slot can also be reasonably set according to needs during the actual use design process.

[0032] In this specific embodiment, the stator inner core 2 includes a plurality of inner iron core sheets arranged along the axial direction, and the stator inner core is formed by stacking the plurality of inner iron core sheets arranged along the axial direction in sequence.

[0033] When the stator slot assembly adopts a structural form of combining a fully enclosed first stator slot and an incompletely enclosed second stator slot, the inner iron core sheets can be staggered when stacked in the axial direction, so that the positions of the incompletely enclosed second stator slots in the axial direction are not completely consistent, thereby forming a straight spiral notch in the axial direction (such as the attached Figure 5 as shown in a), Z-shaped spiral groove (as shown in the attached Figure 5 b), V-shaped spiral groove (as shown in the attached Figure 5 c in the figure), multi-layer overlapping overall offset notches (as shown in the attached Figure 5 d in the figure) and other axial combination forms are used to optimize the magnetic circuit structure. When performing the staggered stacking of the inner iron core sheets, each inner iron core sheet can be staggered in sequence, or multiple inner iron core sheets can be grouped together, and each group of inner iron core sheets can be staggered in sequence. The specific staggered stacking method can be reasonably set according to the actual design.

[0034] In addition, a method for processing a stator structure with a separated tooth yoke portion is also provided in this embodiment, including a method for processing a stator outer core, a method for processing a stator inner core, and a method for assembling a stator winding.

[0035] Specifically, the stator outer core processing method is as follows: the stator outer core 1 is made of non-oriented silicon steel sheets, amorphous alloys, SMC and other soft magnetic materials, and is formed by stamping the whole circle and then stacking the single pieces (such as the attached Figure 6 As shown in a), a single-piece chain structure is wound and stacked (as shown in the attached Figure 6 b), split into two pieces and then stamped and then rotated and bonded (as shown in the attached Figure 6 d in the figure), or by splicing and assembling the petals (as shown in the attached figure Figure 6 (as shown in c) and other forms to form a complete stator outer core.

[0036] When selecting materials for stator outer core processing, non-oriented silicon steel sheets are named because of the irregular distribution of internal grain orientation after rolling and annealing, and the Si content is usually between 0.5% and 3.2%. This material is a Fe-Si or Fe-Si-Al soft magnetic alloy with extremely low carbon content and magnetic isotropy, mainly used in medium and large motors, generators and other electronic components. The physical properties of non-oriented silicon steel sheets include density, resistivity and thermal conductivity, which determine the performance, volume and weight of the motor. Its magnetic properties are mainly reflected in magnetic induction intensity and core loss. For drive motors, these properties determine power density, energy conversion efficiency and working stability. Amorphous alloys, also known as "liquid metal" or "metallic glass", are a new type of soft magnetic alloy material, mainly containing elements such as iron, silicon, and boron. Amorphous metal materials do not have long-range ordered structures, but only short-range and medium-range order. This characteristic allows amorphous alloys to form disordered structures during rapid cooling. Compared with non-oriented silicon steel, amorphous alloy materials have the advantages of low loss, energy saving and environmental protection. The loss density is only 1 / 5~1 / 10 of that of traditional silicon steel sheets, which helps to improve efficiency, reduce noise and heat. SMC is a block material that is formed by coating the surface of iron powder particles with insulating material through a powder metallurgy process. SMC materials have the advantages of isotropy and low eddy current loss coefficient. They are suitable for ultra-high-speed permanent magnet synchronous motor design and can effectively reduce the iron loss of the motor. Compared with traditional electrical silicon steel sheets, SMC materials have much less iron loss than silicon steel sheets under high-frequency conditions and have good magnetic conductivity. These three materials have their own advantages. When choosing, you need to decide which material to use based on the specific design requirements and application scenarios of the motor.

[0037] When processing the stator outer core 1, when the whole circle is stamped and then the single pieces are stacked and formed, as shown in the attached Figure 6As shown in a in the figure, a single-piece stator outer core is first formed by stamping, and then the formed single-piece stator outer core is stacked in sequence along the axial direction to finally form a stator outer core.

[0038] When the stator outer core 1 is formed by winding and stacking a single-piece chain structure, as shown in the attached Figure 6 As shown in b, a single-piece chain structure is used to rotate around the circumference first, and then rotate around the axial direction, similar to the winding method of a spring, and finally form a complete stator outer core.

[0039] When the stator outer core 1 is formed by splitting and then rotating and bonding, as shown in the attached Figure 6 As shown in d, a three-part structure can be adopted, that is, each single-piece stator outer core is formed by rotating and bonding three petals. During the rotation bonding, the overlapping part can select the overlapping range according to the number of tooth slots, and rotate and overlap in sequence, or each full-circle stator punching piece is spliced ​​and then rotated and spliced ​​as a whole; a six-part structure can also be adopted, each single-piece stator outer core is formed by rotating and bonding six petals. During the rotation bonding, the overlapping part can select the overlapping range according to the number of tooth slots, and rotate and overlap in sequence, or each full-circle stator punching piece is spliced ​​and then rotated and spliced ​​as a whole. Of course, during the specific design, the number of petals of each single-piece stator outer core can be specifically selected according to the design and process requirements, and they will not be listed one by one in this specific embodiment.

[0040] When the stator outer core 1 is assembled by splitting and splicing, as shown in the attached Figure 6 As shown in c, two petals can be spliced ​​and assembled to form a shape, three petals can be spliced ​​and assembled to form a shape, or four petals, five petals, six petals... and other methods can be used to assemble and form a shape. During the specific design, the number of petals for assembly can be selected according to the design and process requirements, and they will not be listed one by one in this specific embodiment.

[0041] In addition, when processing the stator outer core 1, it is also necessary to process a first matching structure 101 that matches the stator inner core on the inner circle of the stator outer core. The first matching structure 101 can be a full circle structure, an irregular groove or a convex structure, and its specific shape includes but is not limited to a semicircular shape, a dovetail shape, a square shape, and any regular or irregular shape, as shown in the attached figure. Figure 2 As shown, the main function of the first matching structure 101 on the stator outer core 1 is to cooperate with the second matching structure 202 at the root of the stator inner core 2 to form a complete motor stator core and provide a conduction path for the magnetic field. The size and shape of the first matching structure 101 can be precisely designed according to the motor performance requirements to optimize the magnetic field distribution.

[0042] In this specific embodiment, the processing method of the stator inner iron core 2 is as follows: the stator inner iron core 2 is formed by a plurality of inner iron core sheets stacked in sequence along the axial direction, and the inner iron core sheets are formed by a plurality of single-piece stator structures 202 rotated and spliced ​​in sequence along the circumferential direction, and two adjacent single-piece stator structures 202 are connected by self-adhesion or dispensing, and the single-piece stator structure 202 has N stator teeth and M stator slots, and N and M are both positive integers.

[0043] Specifically, a second matching structure 201 adapted to the first matching structure 101 on the stator outer core 1 needs to be processed on the outer circle of the stator inner core 2, as shown in the attached figure. Figure 3 As shown, when the first matching structure 101 is a semicircular groove structure, the second matching structure 201 is also a semicircular protrusion structure adapted thereto; when the first matching structure 101 is a dovetail groove structure, the second matching structure 201 is also a dovetail protrusion structure adapted thereto, and when the dovetail groove structure is adopted, arc-shaped fillets are provided at the corner positions to avoid stress concentration problems; when the first matching structure 101 is a square groove structure, the second matching structure 201 is also a square protrusion structure adapted thereto, and when the square groove structure is adopted, arc-shaped fillets are provided at the corner positions to avoid stress concentration problems.

[0044] Specifically, as attached Figure 7 As shown, the monolithic stator structure 202 can be directly processed and formed using non-oriented or oriented silicon steel sheets, or first processed into an initial monolithic structure 203, the notch position of the initial monolithic structure 203 is in a closed state, and then shaped to form a monolithic stator structure 202 that meets technical requirements. When determining the material of the monolithic stator structure, the material of the monolithic stator structure can be selected according to actual needs.

[0045] During specific design, the single-piece stator structure 202 may have two stator teeth and one stator slot, or three stator teeth and two stator slots, or four stator teeth and three stator slots, etc. The number of stator teeth and stator slots on the specific single-piece stator structure can be selected according to the requirements of design and process, and will not be listed one by one in this specific embodiment.

[0046] In this specific embodiment, as shown in the attached Figure 8 As shown, the stator slot 204 machined on the monolithic stator structure 202 may be rectangular (as shown in the attached Figure 8 (a) in the figure), symmetrical step type (for example, a step is set on both sides of the stator slot close to the inner circle of the stator core, so that the stator slot as a whole has a symmetrical two-step structure, as shown in the attached figure). Figure 8(b) in the figure), symmetrical multi-layered ladder type (for example, multiple steps are arranged on both sides of the stator slot close to the inner circle of the stator core, so that the stator slot as a whole is a symmetrical multi-layered ladder structure, as shown in the attached figure). Figure 8 (c) in the figure), asymmetric step type (for example, a step is set on one side of the stator slot close to the inner circle of the stator core, so that the stator slot as a whole has an asymmetric step structure, as shown in the attached figure Figure 8 The specific stator slot type is selected according to the design and process requirements, and will not be listed one by one in this specific embodiment.

[0047] In addition, the slot position of the stator slot 204 can also be designed to any shape according to needs. Common slot position shapes are as shown in the following: Fig. 9 As shown in (a), both ends of the monolithic stator structure 202 may extend outward or not extend outward, and the structure of the outward extending portion may also be in various structural forms, such as the attached Fig. 9 (b). Of course, in the specific design, it can also be designed into other shapes according to the design and process requirements to better optimize the magnetic circuit structure.

[0048] In this specific embodiment, when the monolithic stator structures 202 are rotated and spliced ​​in sequence along the circumferential direction, different arrangements of two adjacent monolithic stator structures 202 can also form different stator slot 204 structures to better optimize the magnetic circuit.

[0049] As attached Figure 4 As shown in (a) of FIG. 1 , in this design, two adjacent monolithic stator structures 202 are connected end to end in sequence, so that the entire stator slot is a fully closed slot; as shown in FIG. Figure 4 As shown in (b) and (c), in this design, there is a certain gap between two adjacent monolithic stator structures, and one end of the monolithic stator structure extends out, so that a semi-closed slot is formed between the two monolithic stator structures, and through design, the semi-closed slot can be evenly spaced or unevenly spaced along the circumferential direction; as shown in the attached Figure 4 As shown in (d) in the figure, in this design, there is a certain gap between two adjacent monolithic stator structures, and both ends of the monolithic stator structure extend outward, so that a symmetrical notch is formed between the two monolithic stator structures; as shown in the figure Figure 4 As shown in (e), in this design, there is a certain gap between two adjacent monolithic stator structures, and both ends of the monolithic stator structure do not extend outward, so that a fully open slot is formed between the two monolithic stator structures. Of course, in the actual design process, the connection relationship between the monolithic stator structures can also be adjusted according to the design and process requirements, so as to form more slot combinations.

[0050] In addition, after the single-piece stator structure 202 is rotated and spliced ​​in sequence along the circumferential direction to form the inner iron core, when the inner iron core is stacked in sequence along the axial direction to form the stator inner iron core, different notches can be formed in the axial direction by staggering the inner iron cores of each layer, so as to better optimize the magnetic circuit. For example, the inner iron cores of each layer can be staggered to form a straight spiral notch (such as the attached Figure 5 (a) in the figure), Z-shaped spiral groove (as shown in the attached Figure 5 (b) in the figure), V-shaped spiral groove (as shown in the attached Figure 5 As shown in (c) in the figure, several layers of inner iron core sheets can also be set as a group, and each group of inner iron core sheets are staggered in sequence, as shown in the attached figure. Figure 5 Specifically, when designing, a suitable staggered arrangement scheme can be selected according to the requirements of design and process, and will not be listed one by one in this specific embodiment.

[0051] Specifically, the stator winding assembly method is: embed the stator winding from the outside of the stator inner core into the stator slot, and then assemble the stator outer core with the stator inner core. Specifically, the stator winding is mainly composed of conductive materials and insulating materials, and its main function is to generate a magnetic field by passing current. Its structural forms include round wire windings, flat wire windings (Hair-pin, I-pin, X-pin, etc.), and especially continuous wave windings. The number of turns and wire diameter of the winding can be reasonably designed according to the specific parameters of the motor such as power and voltage to ensure that the motor can achieve optimal performance under different working conditions.

[0052] In summary, compared with the prior art, the present invention adopts the structural design of the stator outer core and the stator inner core, and forms a stator tooth portion on the stator inner core, and forms a stator yoke portion on the stator outer core, so as to form a special stator structure with a separated tooth yoke portion of the present invention, and solve the problem of W-pin winding embedding process. The magnetic field distribution can be optimized by different notch structures, and the vibration and noise problems caused by the electromagnetic force generated during the operation of the motor to new energy vehicles can be reduced. The cross-sectional area of ​​the copper wire is increased by different slot designs, and the motor operation efficiency is improved. By rotating the bonding form, the material cost is reduced, and the loss caused by welding and riveting is reduced. In the present invention, the stator outer core adopts high-quality soft magnetic materials such as non-oriented silicon steel sheets, amorphous alloys, and SMC, which have excellent magnetic conductivity. Its molding method includes single-piece stacking molding after full-circle stamping, single-piece chain structure winding and stacking molding, split-petal stamping and then rotary bonding molding, or split-petal splicing and assembly molding, etc., to form a complete stator outer core. The inner and outer surfaces of the stator outer core are designed with a first matching structure according to specific requirements. The first matching structure can be an irregular groove or protrusion structure. This structure on the inner surface of the stator outer core is mainly used to closely match with the second matching structure of the stator inner core to form a complete stator core, thereby providing an efficient conduction path for the magnetic field. The size and shape of the first matching structure and the second matching structure can be precisely designed according to the performance requirements of the motor, so as to achieve the purpose of optimizing the magnetic field distribution. The special structure on the outer surface of the stator outer core is mainly used to match with the motor casing to fix the stator structure, or to form an oil channel to facilitate the heat dissipation of the motor. Similarly, its size and shape are also designed according to the performance requirements of the motor to achieve the purpose of optimizing the stability of the stator structure. The stator inner core is made of multiple single-piece stator structures that are rotated and stacked into inner iron chips one by one by self-adhesion or dispensing. The single-piece stator structure is directly processed from non-oriented or oriented silicon steel sheets, or pre-processed into an initial single-piece structure, and then formed into a single-piece stator structure through later shaping). The slot position of the single-piece stator structure is closed. The tooth structure of the monolithic stator structure has N teeth (N is a positive integer), and the shape of its slot position can be flexibly adjusted to any shape according to design requirements, so as to optimize the magnetic circuit structure. Moreover, the slot position at the joint of two adjacent monolithic stator structures can change the size and shape of the joint position according to actual needs. Through rotational splicing, a variety of slot combinations are finally formed in the circumferential direction, including fully closed slots, evenly spaced semi-closed slots in the circumferential direction, unevenly spaced semi-closed slots in the circumferential direction, evenly spaced symmetrical slots in the circumferential direction, and evenly spaced fully open slots. The magnetic circuit structure can also be further optimized by displacing the inner iron core sheet in the axial direction to form a straight spiral slot, a Z-shaped spiral slot, a V-shaped spiral slot, a multi-layer overlapping overall displaced slot, etc.

[0053] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present invention rather than to limit the technical solution. Those skilled in the art should understand that those modifications or equivalent substitutions of the technical solution of the present invention that do not depart from the purpose and scope of the technical solution should be included in the scope of the claims of the present invention.

Claims

1. A stator structure with a separated tooth yoke, characterized in that: The invention comprises a stator core and a stator winding, wherein the stator core comprises a stator outer core and a stator inner core, a stator tooth portion is formed on the stator inner core, and a stator yoke portion is formed on the stator outer core, so that the stator tooth portion and the stator yoke portion of the stator core are separated.

2. The stator structure with separated tooth yoke parts according to claim 1, characterized in that: A first matching structure is provided on the inner circle of the stator outer core, and a second matching structure adapted to the first matching structure is provided on the outer circle of the stator inner core, so that a complete stator core is formed through the mutual cooperation of the first matching structure and the second matching structure.

3. The stator structure with separated tooth yoke parts according to claim 2, characterized in that: The stator inner core is provided with a stator slot assembly, and the stator slot assembly includes a plurality of stator slots with fully enclosed slot openings.

4. The stator structure with separated tooth yoke parts according to claim 2, characterized in that: The stator inner core is provided with a stator slot assembly, which includes a plurality of first stator slots and a plurality of second stator slots. The first stator slots have fully enclosed slot openings, and the second stator slots have incompletely enclosed slot openings.

5. The stator structure with separated tooth yoke parts according to claim 4, characterized in that: A plurality of the second stator slots are arranged in a set manner in the circumferential direction, and the second stator slots are semi-closed slots, symmetrical slots or fully open slots.

6. The stator structure with separated tooth yoke parts according to claim 4, characterized in that: The stator inner core includes a plurality of inner core sheets arranged along the axial direction, and positions of the second stator slots on different inner core sheets are not completely the same.

7. A method for processing a stator structure with a separated tooth yoke portion as claimed in claim 1, characterized in that: The invention comprises a stator outer iron core processing method, a stator inner iron core processing method and a stator winding assembly method.

8. The method for processing a stator structure with a separated tooth yoke portion according to claim 7, characterized in that: The processing method of the stator outer core is as follows: the stator outer core is formed by stamping a whole circle and then stacking a single piece, winding and stacking a single piece chain structure, stamping a petal and then rotating and bonding it, or splicing and assembling a petal.

9. The method for processing a stator structure with a separated tooth yoke portion according to claim 7, characterized in that: The processing method of the stator inner iron core is as follows: the stator inner iron core is formed by stacking a plurality of inner iron core sheets in sequence along the axial direction, the inner iron core sheets are formed by rotating and splicing a plurality of single-piece stator structures in sequence along the circumferential direction, and two adjacent single-piece stator structures are connected by self-adhesion or dispensing, and the single-piece stator structure has N stator teeth and M stator slots, and N and M are both positive integers.

10. The method for processing a stator structure with a separated tooth yoke portion according to claim 7, characterized in that: The stator winding is assembled by inserting the stator winding into the stator slot from the outside of the stator inner core, and then assembling the stator outer core and the stator inner core.

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