Stator core structure, preparation method and new energy automobile driving motor

Abstract

The invention relates to the technical field of motors, and particularly provides a stator core structure, which comprises an annular body formed by laminating a plurality of core sheets, the iron core sheet is made of an amorphous alloy material; a plurality of semi-open groove-shaped structures are uniformly distributed on the inner circumference of the annular body, and tooth parts are formed between the annular body and the adjacent groove-shaped structures; a plurality of protrusion positioning structures are arranged on the surface of one side of each iron core sheet, and pit positioning structures matched with the protrusion positioning structures are arranged at the corresponding positions of the other side of each iron core sheet. A plurality of welding grooves are evenly distributed in the outer edge of the iron core sheet, and the annular body is filled with welding flux through the welding grooves to be welded and fixed. The motor iron core structure is optimally designed, and the electromagnetic performance is improved by adopting an amorphous alloy material; a pear-shaped chute structure is adopted, the slot fullness rate is increased, the loss is reduced, and the working condition efficiency is improved; the trapezoidal buckling points are adopted, positioning and connection of the stacking process are facilitated, and the semicircular welding grooves are adopted, so that the overall strength of the iron core is improved. The motor iron core which is small in size, excellent in performance and good in stability is finally obtained through optimization design.

Description

Technical Field

[0001] The present invention belongs to the technical field of motors, and in particular relates to a stator core structure, a preparation method and a new energy vehicle drive motor. Background Art

[0002] As one of the core components of new energy vehicles, the drive motor is the key to the conversion of electrical energy into mechanical energy. With the rapid development of the new energy vehicle industry, the performance and energy efficiency requirements of motors are constantly increasing. Permanent magnet synchronous motors have excellent performance under high frequency and high speed conditions, which can improve the power performance and cruising range of new energy vehicles. Since the development of permanent magnet synchronous motors, motor core loss has been the main factor affecting the motor's operating efficiency, and miniaturization and lightweighting are the development trend. Therefore, the development of small size, low loss, high performance motor cores has important application value and huge market demand for new energy vehicles.

[0003] At present, the main disadvantage of the motor core is the large space volume. The current power density of the core in the industry is about (4-6) KW / kg. In order to meet the high-power and high-speed operation of the automobile, the volume of the motor core needs to be increased. This is mainly because the traditional silicon steel sheet core structure is unreasonable, resulting in complex magnetic field distribution of the motor, high energy loss and low efficiency. The volume of the core must be increased to meet the driving force of the motor.

[0004] To this end, the present invention provides a stator core structure to solve the above problems. Summary of the invention

[0005] In order to overcome the deficiencies of the prior art, the present invention provides a stator core structure to solve the problems in the prior art.

[0006] One embodiment of the present invention provides a stator core structure, comprising:

[0007] A ring-shaped body formed by laminating a number of iron core sheets;

[0008] The iron core sheet is made of amorphous alloy material;

[0009] A plurality of semi-open groove structures are evenly distributed on the inner circumference of the annular body, and teeth are formed between adjacent groove structures;

[0010] A plurality of protruding positioning structures are arranged on one side of the core sheet, and a concave positioning structure cooperating with the protruding positioning structure is arranged at a corresponding position on the other side;

[0011] A plurality of welding grooves are evenly distributed on the outer edge of the core sheet, and the annular body is fixed by welding by filling the welding grooves with solder.

[0012] In one of the embodiments, the amorphous alloy material is a FeSiB alloy, wherein the mass fraction of Fe is 50-100%, the mass fraction of Si is 0-20%, and the mass fraction of B is 0-20%.

[0013] In one embodiment, the semi-open groove structure is a pear-shaped groove, the opening width of which is 30-50% of the maximum width of the groove body, and the width of the tooth portion increases radially from inside to outside with an increasing gradient of 0.1-0.3 mm / groove.

[0014] In one of the embodiments, the raised positioning structure is a trapezoidal buckle point, with four buckle points evenly distributed on a single side surface, the shape of the recessed positioning structure is complementary to the raised buckle point, and the central angle between adjacent buckle points is 80-100°.

[0015] In one embodiment, the trapezoidal base length of the trapezoidal buckle point is 1-3 mm, and the height is 0.5-1.2 mm.

[0016] In one of the embodiments, the welding groove is a semicircular groove with an arc radius of 0.8-1.5 mm and a depth of 50-80% of the thickness of the iron core sheet. The number of welding grooves is 6-8.

[0017] In one embodiment, it also relates to a method for preparing the stator core structure as described in any one of the above items, comprising the following steps:

[0018] Stamping: Use progressive die to punch out the core sheet, and simultaneously form the groove structure, protrusion positioning structure, pit positioning structure and welding groove;

[0019] Stacking positioning: stacking the iron core sheets in the order of the convex and concave matching of the convex and concave positioning structures to form a pre-assembled iron core;

[0020] Welding reinforcement: Fill the welding grooves of the pre-assembled core with solder and perform laser welding to obtain a formed stator core.

[0021] In one of the embodiments, it also involves a new energy vehicle drive motor, comprising a stator core structure as described in any of the above items, and a skewed slot H-shaped flat wire winding is embedded in the slot structure, and the skewed slot inclination is 0-30°.

[0022] The stator core structure provided in the above embodiments has the following beneficial effects:

[0023] The motor core structure is optimized and designed, and amorphous alloy materials are used to improve electromagnetic performance; a pear-shaped inclined slot structure is used to increase the slot fill rate, reduce losses, and improve working efficiency; a trapezoidal buckle point is used to facilitate the positioning and connection of the stacking process, and a semi-circular welding slot is used to improve the overall strength of the core. Through the optimized design, a motor core with small size, superior performance and good stability is finally obtained. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the structures shown in these drawings without paying creative work.

[0025] Figure 1 A schematic diagram of the overall structure of a stator core structure provided by an embodiment of the present invention;

[0026] Figure 2 A front schematic diagram of a stator core structure provided by an embodiment of the present invention;

[0027] Figure 3 A schematic diagram of the reverse side of a multilayer composite material provided by an embodiment of the present invention;

[0028] Figure 4 A schematic diagram of the core sheet structure of the stator core structure provided in an embodiment of the present invention.

[0029] Figure Number:

[0030] 100, annular body; 200, iron core sheet; 300, groove structure; 400, tooth portion; 500, protrusion positioning structure; 600, recessed positioning structure; 700, welding groove. DETAILED DESCRIPTION

[0031] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0032] It should be noted that if the embodiments of the present invention involve directional indications (such as up, down, left, right, front, back, etc.), the directional indications are only used to explain the relative position relationship, movement status, etc. between the components in a certain specific posture. If the specific posture changes, the directional indication will also change accordingly.

[0033] In addition, if there are descriptions involving "first", "second", etc. in the embodiments of the present invention, the descriptions of "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Therefore, the features limited to "first" and "second" may explicitly or implicitly include at least one of the features. In addition, if "and / or" or "and / or" appears in the full text, its meaning includes three parallel solutions. Taking "A and / or B" as an example, it includes solution A, solution B, or solutions that satisfy both A and B. In addition, the technical solutions between the various embodiments can be combined with each other, but it must be based on the ability of ordinary technicians in this field to implement. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0034] Reference Figure 1-Figure 4 One embodiment of the present invention provides a stator core structure, including:

[0035] The annular body 100 is formed by laminating a plurality of iron core sheets 200;

[0036] The core sheet 200 is made of amorphous alloy material;

[0037] A plurality of half-open slot structures 300 are evenly distributed on the inner circumference of the annular body 100, and teeth 400 are formed between adjacent slot structures 300;

[0038] The core sheet 200 is provided with a plurality of protruding positioning structures 500 on one side thereof, and a concave positioning structure 600 cooperating with the protruding positioning structure 500 is provided at a corresponding position on the other side thereof;

[0039] A plurality of welding grooves 700 are evenly distributed on the outer edge of the core sheet 200 , and the annular body 100 is fixed by welding by filling the welding grooves 700 with solder.

[0040] In this embodiment, the amorphous alloy material is a FeSiB alloy, wherein the mass fraction of Fe is 50-100%, the mass fraction of Si is 0-20%, and the mass fraction of B is 0-20%.

[0041] In this embodiment, the semi-open groove structure 300 is a pear-shaped groove, the opening width of which is 30-50% of the maximum width of the groove body, and the width of the tooth portion 400 increases radially from inside to outside, with an increasing gradient of 0.1-0.3 mm / groove.

[0042] In this embodiment, the raised positioning structure 500 is a trapezoidal buckle point, with four buckle points evenly distributed on a single side surface, and the shape of the recessed positioning structure 600 is complementary to the raised buckle point, and the central angle between adjacent buckle points is 80-100°.

[0043] In this embodiment, the length of the trapezoidal base of the trapezoidal buckle point is 1-3 mm, and the height is 0.5-1.2 mm.

[0044] In this embodiment, the welding groove 700 is a semicircular groove with an arc radius of 0.8-1.5 mm and a depth of 50-80% of the thickness of the core sheet 200 . The number of the welding grooves 700 is 6-8.

[0045] As described in the above embodiment:

[0046] The amorphous alloy material is FeSiB alloy, in which the mass fraction of Fe is 50-100%, the mass fraction of Si is 0-20%, and the mass fraction of B is 0-20%.

[0047] The electromagnetic performance can be improved by using an amorphous alloy to make the iron core sheet 200; the amorphous alloy material is a FeSiB alloy, with a mass fraction of Fe of 50-100%, a mass fraction of Si of 0-20%, and a mass fraction of B of 0-20%, which can maintain the amorphous state forming ability and avoid the degradation of magnetic properties caused by crystallization.

[0048] By designing multiple semi-open slot structures 300, the cross-sectional area of ​​the slot bottom is expanded, and the slot fill rate is increased, so that the loss is reduced, the working efficiency is improved, more winding wires are allowed, and the output torque is improved; the semi-open slot structure 300 adopts a pear shape, and the semi-open pear-shaped slot has a large internal space and a larger cross-sectional area for placing the winding, thereby improving the slot fill rate; the opening is smaller, and the corresponding tooth width is increased, which can improve the mechanical strength of the stator.

[0049] A plurality of iron core sheets 200 are stacked to form an annular body 100 as a stator iron core structure. During the stacking process, a fixing method combining riveting and welding is adopted. The rivets play a fixing role on the one hand, and also play a role in lamination and positioning on the other hand. However, the bonding force is not enough if the rivets are used alone, and the rigidity of the entire iron core is also relatively lacking. Therefore, by strengthening it by welding, the deformation caused by high-frequency vibration can be reduced.

[0050] The rivet buckle structure is a raised positioning structure 500 and a corresponding concave positioning structure 600 provided on the surface of the core sheet 200. The raised positioning structure 500 is a peanut-shaped trapezoidal buckle point. The peanut trapezoidal structure is convenient for positioning and stacking. In addition, the peanut trapezoidal shape can increase the friction area between the positioning protrusion and the concave pit, thereby improving the friction force and increasing the overall strength of the core after assembly. The peanut trapezoidal buckle point increases the side cross-sectional area. When the two stacked sheets are riveted, there is greater friction force and better circumferential constraint force. Therefore, the riveting is tighter and firmer; 4 buckle points are evenly distributed on the single side surface, and the concave positioning structure 6 The shape of 00 is complementary to the raised buckle point, and the central angle between adjacent buckle points is 80-100°. The central angle of 80-100° makes the circumferential distribution uniformity optimal and avoids the ovality deviation (≤0.02mm) caused by uneven force on the stacking sheets; among them, the trapezoidal bottom edge length of the trapezoidal buckle point is 1-3mm, and the height is 0.5-1.2mm. If the bottom edge is too small (<1mm), it is easy to be punched and broken, and if the bottom edge is too large (>3mm), it will occupy too much slot space. The height of 0.5-1.2mm ensures sufficient buckling depth (stacking misalignment force ≥100N / buckle point) and avoids excessive deformation of the material.

[0051] The welding groove 700 is used to provide a position for welding, making the welding process convenient; the welding groove 700 is a semicircular groove with an arc radius of 0.8-1.5mm, which can be filled with more solder and easily irradiated by the laser source, avoiding the existence of welding defects. Among the semicircular grooves, one is a U-shaped groove, and the existence of the U-shaped groove facilitates stacking and positioning; the depth is 50-80% of the thickness of the iron core sheet 200. If the thickness is too shallow (<50%), it will lead to insufficient welding strength. If the thickness is too deep (>80%), it will be easy to crack due to punching. The number of welding grooves 700 is 6-8, and the density of circumferential welding points balances strength and heat input. The area of ​​the heat-affected zone is ≤2% of the surface area of ​​the iron core.

[0052] In one embodiment, it also relates to a method for preparing the stator core structure as described in any one of the above items, comprising the following steps:

[0053] Stamping: using a progressive die to punch out the core sheet 200, and simultaneously forming the groove structure 300, the protruding positioning structure 500, the concave positioning structure 600 and the welding groove 700;

[0054] Stacking and positioning: stacking the iron core sheets 200 in the order of the protruding positioning structure 500 and the concave positioning structure 600 to form a pre-assembled iron core;

[0055] Welding reinforcement: The welding groove 700 of the pre-installed core is filled with solder and laser welded to obtain a formed stator core.

[0056] In this embodiment, a one-time forming groove, buckle point, and welding groove 700 are adopted, and the dimensional accuracy is ±0.01mm, which is improved compared with the step-by-step processing efficiency; a plurality of core sheets 200 are stacked into an annular body 100 as a stator core structure, and a fixing method combining riveting and welding is adopted in the stacking process. The rivets play a fixing role on the one hand, and also play a role in lamination and positioning on the other hand. However, the bonding force is not enough if the rivets are relied on alone, and the rigidity of the entire core is also relatively lacking. Therefore, by strengthening it by welding, the deformation caused by high-frequency vibration can be reduced; the welding power is 800-1200W, and the welding speed is 0.5-1.2m / min. The power of 800-1200W can ensure a penetration depth of 0.3-0.8mm, and the speed of 0.5-1.2m / min controls the heat input, and the width of the amorphous alloy annealing zone is ≤0.1mm (the magnetic permeability decreases by <3%).

[0057] In one of the embodiments, a new energy vehicle drive motor is also involved, comprising a stator core structure as described in any of the above items, and a skewed slot H-shaped flat wire winding is embedded in the slot structure 300, and the skewed slot inclination is 0-30°.

[0058] In this embodiment, the skewed slot structure increases the utilization rate of the slot area and can accommodate more windings, thereby improving the power density of the core;

[0059] Further, the slope of the chute is 5-25°;

[0060] A slope of less than 5° will result in insufficient harmonic suppression, and a slope of more than 25° will make the winding end too long, increase copper loss, and increase process difficulty.

[0061] As needed, the above-mentioned installation, setting, provision or connection methods include but are not limited to installation, setting or connection by screws, riveting, welding or socketing, fixing, etc., and the installation, setting or connection method is selected according to the needs of the working scenario.

[0062] The above description is only a preferred embodiment of the present invention, and does not limit the patent scope of the present invention. All equivalent structural changes made by using the contents of the present invention specification and drawings under the inventive concept of the present invention, or directly / indirectly applied in other related technical fields are included in the patent protection scope of the present invention.

Claims

1. A stator core structure, characterized in that: include: A ring-shaped body formed by laminating a number of iron core sheets; The core sheet is made of amorphous alloy material; A plurality of semi-open groove structures are evenly distributed on the inner circumference of the annular body, and teeth are formed between adjacent groove structures; A plurality of protruding positioning structures are arranged on one side of the core sheet, and a concave positioning structure cooperating with the protruding positioning structure is arranged at a corresponding position on the other side; A plurality of welding grooves are evenly distributed on the outer edge of the core sheet, and the annular body is fixed by welding by filling the welding grooves with solder.

2. The stator core structure according to claim 1, characterized in that: The amorphous alloy material is a FeSiB alloy, wherein the mass fraction of Fe is 50-100%, the mass fraction of Si is 0-20%, and the mass fraction of B is 0-20%.

3. The stator core structure according to claim 1, characterized in that: The semi-open groove structure is a pear-shaped groove, the opening width of which is 30-50% of the maximum width of the groove body, and the width of the tooth portion increases radially from inside to outside, with an increasing gradient of 0.1-0.3 mm / groove.

4. The stator core structure according to claim 1, characterized in that: The raised positioning structure is a trapezoidal buckle point, with four buckle points evenly distributed on a single side surface. The shape of the recessed positioning structure is complementary to the raised buckle point, and the central angle between adjacent buckle points is 80-100°.

5. The stator core structure according to claim 4, characterized in that: The trapezoidal bottom side length of the trapezoidal buckle point is 1-3 mm, and the height is 0.5-1.2 mm.

6. The stator core structure according to claim 1, characterized in that: The welding groove is a semicircular groove with an arc radius of 0.8-1.5 mm and a depth of 50-80% of the thickness of the iron core sheet. The number of the welding grooves is 6-8.

7. A method for preparing a stator core structure according to any one of claims 1 to 6, characterized in that: The steps include: Stamping: Use progressive die to punch out the core sheet, and simultaneously form the groove structure, protrusion positioning structure, pit positioning structure and welding groove; Stacking positioning: stacking the iron core sheets in the order of the convex and concave matching of the convex and concave positioning structures to form a pre-assembled iron core; Welding reinforcement: Fill the welding grooves of the pre-assembled core with solder and perform laser welding to obtain a formed stator core.

8. A new energy vehicle drive motor, characterized in that: It comprises the stator core structure as claimed in any one of claims 1 to 6, wherein the slot-shaped structure is embedded with an H-shaped flat wire winding with an inclined slot having an inclination of 0-30°.

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