Rolling stator structure, external rotor motor and manufacturing method of external rotor motor

Abstract

The invention discloses an edge rolling stator structure, an external rotor motor and a manufacturing method thereof. The edge rolling stator structure comprises a coil holder; the plurality of iron cores are arranged in the coil holder and are provided with tooth parts, one end of each tooth part is provided with a yoke part, the other end of each tooth part is provided with a shoe part, each tooth part is provided with a butt joint structure, the yoke parts of two adjacent iron cores are in butt joint with each other through the butt joint structures, and the shoe parts of two adjacent iron cores are connected through a connecting bridge; the distance between every two adjacent yoke parts on the iron core is large, winding equipment can easily penetrate through the yoke parts to conduct winding, winding is easier, the winding efficiency is improved, winding can be more convenient due to the fact that winding can be conducted between the tooth parts with the larger distance, the winding slot fullness rate can be more easily improved, and the winding efficiency is improved. And the winding mode does not need to pass through a notch between the shoe parts, so that the notch between the shoe parts can be set to be smaller to reduce the cogging torque.

Description

Technical Field

[0001] The present invention relates to the field of external rotor motors, and in particular to a rolled stator structure, an external rotor motor and a manufacturing method thereof. Background Art

[0002] An external rotor motor (Electric Motor) is a device that converts electrical energy into mechanical energy based on the principle of electromagnetic induction. It is widely used in industries, transportation, home appliances, etc. Its core function is to generate torque through the interaction between electromagnetic fields and currents to drive mechanical motion.

[0003] The types of outer rotor motors include inner rotor outer rotor motors and outer rotor outer rotor motors. The core feature of inner rotor outer rotor motors is that the rotor is located inside the stator, usually composed of permanent magnets or electromagnets, while the stator is composed of winding coils; outer rotor outer rotor motors are a special structure of outer rotor motors, whose rotor is located outside the stator, and the stator is fixed in the center position, and the rotor is driven to rotate through magnetic field interaction.

[0004] The stator is the stationary part of an external rotor motor. It usually consists of an iron core and windings. The iron core is laminated with silicon steel sheets to reduce eddy current losses. The windings generate a magnetic field when energized. In an AC external rotor motor, the stator winding forms a rotating magnetic field through a three-phase current; in a DC external rotor motor, the stator may contain permanent magnets or electromagnets.

[0005] In the design of conventional outer rotor motors, the stator generally adopts a full-circle iron core structure, which is composed of multiple adjacent teeth. A boot is provided at one end of each tooth, and a slot is formed between adjacent boots. In order to ensure the smooth progress of the winding process, a large slot space needs to be reserved between adjacent teeth so that the winding equipment can pass smoothly and complete the winding operation on the teeth. If the slot is designed to be too narrow, it will lead to problems such as difficulty in winding, reduced winding efficiency, and insufficient slot fill rate. However, too large a slot will cause an increase in cogging torque. Summary of the invention

[0006] In order to overcome the disadvantages of the prior art that a whole round iron core is used, the iron core includes a plurality of adjacent teeth, one end of the tooth has a boot, and there are slots between the boots. In order to facilitate winding, a larger slot is required between adjacent teeth. The winding equipment winds the wire on the tooth through the slot. If the slot is too narrow, it will cause winding difficulties, low winding efficiency, and low slot fill rate.

[0007] First aspect

[0008] The present invention provides a rolled stator structure, comprising:

[0009] Wire rack;

[0010] A plurality of iron cores are installed in a bobbin and are provided with a tooth portion, a yoke portion is provided at one end of the tooth portion, a boot portion is provided at the other end of the tooth portion, a butt joint structure is provided on the tooth portion, the yoke portions of two adjacent iron cores are butt jointed with each other through the butt joint structure, and the boot portions of two adjacent iron cores are connected through a connecting bridge.

[0011] Optionally, the docking structure includes a mortise and a tenon, and the mortise and the tenon are respectively arranged on both sides of the yoke, and the yokes of two adjacent iron cores are docked through the cooperation of the tenon and the mortise.

[0012] Optionally, multiple iron cores are arranged in sequence, and the boot portion of the first iron core and the boot portion of the last iron core in the arrangement order are welded and fixed.

[0013] Optionally, the thickness of the connecting bridge is 0.3-1 mm.

[0014] Optionally, there is a notch between two adjacent shoe parts, and the width of the notch is 0-2 mm.

[0015] Optionally, the wire rack includes an upper frame sleeve and a lower frame sleeve, the upper frame sleeve is connected to the lower frame sleeve, an accommodating cavity is formed between the upper frame sleeve and the lower frame sleeve, and the tooth portion is located in the accommodating cavity.

[0016] Optionally, a first limiting portion and a second limiting portion are provided on the upper frame sleeve, the first limiting portion and the second limiting portion are respectively located at two ends of the upper frame sleeve, and a PIN needle connecting groove is provided on the first limiting portion.

[0017] Optionally, a third limiting portion and a fourth limiting portion are provided on the lower frame sleeve, and the third limiting portion and the fourth limiting portion are respectively located at two ends of the upper frame sleeve.

[0018] Second aspect

[0019] The present invention provides an outer rotor motor, comprising: the rolled stator structure according to any one of claims 1 to 8.

[0020] The third aspect

[0021] The present invention provides a method for manufacturing a rolled stator structure, comprising the following steps:

[0022] Stamping and riveting: Silicon steel sheets are processed by stamping and riveting to form multiple iron cores, and adjacent iron cores are connected by connecting bridges;

[0023] Winding, placing multiple cores into a bobbin and winding enameled wire around the bobbin to form a winding;

[0024] Rolling, rolling the iron core with winding after winding by tooling;

[0025] Welding: After rolling, the boot of the first core is butted against the boot of the last core in the order of arrangement, and the boot of the first core is connected and fixed to the boot of the last core by welding;

[0026] Plastic coating: plastic coating the rolled core BMC to form a whole with the core and winding;

[0027] Turning: Turn the entire outer circle after plastic coating to remove the connecting bridge on the periphery of the core.

[0028] The beneficial effects of the present invention are as follows: before rolling, multiple iron cores are connected by a connecting bridge, the yokes of the iron cores are not butted against each other, and the multiple iron cores are arranged in parallel with a large spacing between the iron cores. The iron core can enter the spacing between the iron cores from one side of the yoke of the iron core during winding by the winding equipment to wind the enameled wire on the wire rack without passing through the slots between the boots. Since the iron cores are not butted against each other, the spacing between two adjacent yokes on the iron core is large, and the winding equipment can easily pass through the yokes for winding, making winding easier and improving winding efficiency. Since the wire can be wound between teeth with larger spacing, winding is more convenient and the winding slot full rate can be improved more easily. Moreover, this winding method no longer needs to pass through the slots between the boots, so the slots between the boots can be set smaller to reduce the tooth slot torque. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The present invention is further described below in conjunction with the accompanying drawings and embodiments.

[0030] Figure 1 is a schematic diagram of the stator structure before rolling in some embodiments;

[0031] Figure 2 is a schematic diagram of a structure of winding and forming on a stator structure before rolling in some embodiments;

[0032] Figure 3 Schematic diagram of structural disassembly of a rolled stator structure in some embodiments;

[0033] Figure 4 is a schematic diagram of the structure of the iron core in some embodiments;

[0034] Figure 5 yes Figure 4 Enlarged view of part A in the middle;

[0035] Figure 6 is a schematic diagram of the structure of the wire rack in some embodiments;

[0036] Figure 7 is a schematic diagram of the stator structure after rolling in some embodiments;

[0037] Figure 8 Schematic diagram of the stator structure after BMC coating in some embodiments;

[0038] Figure 9 is a schematic diagram of the BMC plastic-coated stator structure after turning in some embodiments;

[0039] Figure 10 Schematic diagram of the stator structure in the housing after turning in some embodiments.

[0040] Figure 11 is a flow chart of a method for manufacturing a rolled stator structure in some embodiments.

[0041] Description of reference numerals:

[0042] 1. bobbin; 2. iron core; 201. tooth portion; 202. yoke portion; 203. boot portion; 204. connecting bridge; 205. mortise; 206. tenon; 207. notch; 101. upper frame; 102. lower frame; 103. first limiting portion; 104. second limiting portion; 105. PIN needle connecting groove; 106. third limiting portion; 107. fourth limiting portion; 3. winding; 4. casing. DETAILED DESCRIPTION

[0043] The following will clearly and completely describe the concept, specific structure and technical effects of the present invention in combination with the embodiments and drawings, so as to fully understand the purpose, characteristics and effects of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, other embodiments obtained by technicians in this field without creative work are all within the scope of protection of the present invention. In addition, all the connection / connection relationships involved in the patent do not refer to the direct connection of components, but refer to the formation of a better connection structure by adding or reducing connection accessories according to the specific implementation situation. The various technical features in the invention can be combined interchangeably without conflicting with each other.

[0044] The present invention provides a rolled stator structure, comprising: a bobbin 1; a plurality of iron cores 2, which are installed in the bobbin 1 and provided with a tooth portion 201, a yoke portion 202 being provided at one end of the tooth portion 201, a boot portion 203 being provided at the other end of the tooth portion 201, a butt joint structure being provided on the tooth portion 201, the yoke portions 202 of two adjacent iron cores 2 being butt jointed with each other via the butt joint structure, and the boot portions 203 of two adjacent iron cores 2 being connected via a connecting bridge 204.

[0045] During implementation, multiple cores 2 are connected by connecting bridges 204, and the bobbin 1 is installed on the core 2 so that the core 2 is located inside the bobbin 1. Multiple cores 2 before rolling are arranged in parallel. The winding equipment passes through the gaps between the yokes 202 of the cores 2 and winds the enameled wire on the bobbin 1 corresponding to the position of each core 2. After winding, multiple cores 2 are rolled by tooling. After rolling, the yokes 202 of the cores 2 are butted against each other through a butt joint structure. The boots 203 of the core 2 are located on the periphery of the whole after rolling, and the connecting bridge 204 is located on the outermost side. After rolling, the stator structure needs to be BMC (Bulk Molding) Compound, bulk molding compound) is used for overmolding the entire stator structure and forming a shell 4 on the outside of the stator structure, and then the outermost connecting bridge 204 is cut by turning to finally form a complete stator structure; before rolling, multiple cores 2 are connected by connecting bridges 204, and the yokes 202 of the cores 2 are not butted against each other. Multiple cores 2 are arranged in parallel, and there is a large spacing between the cores 2. The cores 2 can enter the spacing between the cores 2 from one side of the yoke 202 of the core 2 during winding equipment to wind the enameled wire on the wire rack 1 without having to pass through The slots 207 between the boots 203 are large in distance between two adjacent yokes 202 on the core 2 because the core 2 is not butt-jointed, and the winding equipment can easily pass through between the yokes 202 for winding, making winding easier and improving winding efficiency. Since winding can be done between the teeth 201 with larger spacing, winding is more convenient and the winding slot full rate can be improved more easily. Moreover, this winding method no longer needs to pass through the slots 207 between the boots 203, so the slots 207 between the boots 203 can be set smaller to reduce the tooth torque.

[0046] Furthermore, the core 2 is formed by stamping and riveting silicon steel sheets, and is divided into a tooth portion 201, a yoke portion 202, and a boot portion 203. The yoke portion 202 and the boot portion 203 are respectively located at the two ends of the tooth portion 201. The cross-sectional area of ​​the yoke portion 202 is larger than the cross-sectional area of ​​the tooth portion 201, and the cross-sectional area of ​​the boot portion 203 is also larger than the cross-sectional area of ​​the tooth portion 201, so that a groove is formed in the middle of the core 2. The wire frame 1 is sleeved on the surface of the tooth portion 201. The wire frame 1 includes a plurality of frame sleeves corresponding to the shape of the tooth portion 201, and each tooth portion 201 is located in each frame sleeve.

[0047] In some embodiments, the docking structure includes a mortise 205 and a tenon 206 , which are respectively arranged on both sides of the yoke 202 , and the yokes 202 of two adjacent cores 2 are docked with the tenon 206 and the mortise 205 .

[0048] During implementation, a mortise 205 and a tenon 206 are respectively provided on both sides of each yoke 202. After a plurality of iron cores 2 are rolled and butted together, the tenons 206 and the mortise 205 of two adjacent yokes 202 are butted together, and the tenon 206 is inserted into the mortise 205 to finally form a closed loop. All yokes 202 are butted together to form an overall circular ring structure. The butt connection of the yoke 202 can be more stable by butting the tenon 206 and the mortise 205.

[0049] In some cases, the docking structure may also be teeth provided on both sides of the yoke 202 , and two adjacent yokes 202 may be docked by the mutual cooperation of the teeth, which can also enable the yokes 202 to be stably docked with each other.

[0050] In some embodiments, a plurality of cores 2 are arranged in sequence, and the shoe portion 203 of the first core 2 and the shoe portion 203 of the last core 2 in the arrangement sequence are welded and fixed.

[0051] During implementation, the multiple cores 2 are arranged in sequence after docking, the leading core 2 and the tail core 2 are docked with each other, the yokes 202 of the two cores 2 are docked through a docking structure, and the boots 203 of the two cores 2 are fixed by welding after docking, thereby ensuring the stability of the whole after rolling.

[0052] Furthermore, the boot of the first core and the boot of the last core are provided with welding strips butting against each other, that is, the first core 2 is provided with a welding strip, and the last core 2 is also provided with a welding strip, and the first core 2 and the last core 2 are fixed by welding through the welding strips.

[0053] In some embodiments, the thickness of the connecting bridge 204 is 0.3-1 mm.

[0054] During implementation, the thickness of the connecting bridge 204 is set to 0.3-1 mm to ensure the structural stability of the connecting bridge 204 when it is bent along with the iron core 2, that is, to ensure that it can be easily bent and not broken.

[0055] Furthermore, the connecting bridge 204 is integrally formed with the iron core 2 . Both the connecting bridge 204 and the iron core 2 are formed by stamping and riveting silicon steel sheets. The connecting bridge 204 is formed by stamping two adjacent boots 203 of the iron core 2 .

[0056] In some embodiments, a notch 207 is provided between two adjacent shoe portions 203 , and the width of the notch 207 is 0-2 mm.

[0057] During implementation, the iron core 2 is formed by stamping, stacking and riveting silicon steel sheets, and there is a notch 207 between the boots 203 of adjacent iron cores 2. The width of the notch 207 is 0-2 mm. A small notch 207 can reduce the cogging torque.

[0058] In some embodiments, the wire rack 1 includes an upper rack sleeve 101 and a lower rack sleeve 102 , the upper rack sleeve 101 is connected to the lower rack sleeve 102 , an accommodating cavity is formed between the upper rack sleeve 101 and the lower rack sleeve 102 , and the tooth portion 201 is located in the accommodating cavity.

[0059] During implementation, the upper frame sleeve 101 is installed above the tooth portion 201, and the lower frame sleeve 102 is installed below the tooth portion 201. The upper frame sleeve 101 and the lower frame sleeve 102 are connected to each other to form a accommodating cavity. The tooth portion 201 is located in the accommodating cavity. The upper frame sleeve 101 and the lower frame sleeve 102 play the role of supporting the iron core 2 and insulation.

[0060] Furthermore, a receiving groove is provided at the bottom of the upper frame cover 101, and a receiving groove is provided at the top of the lower frame cover 102, and a receiving cavity is formed by docking the receiving groove of the upper frame cover 101 with the receiving groove of the lower frame cover 102.

[0061] In some embodiments, the upper frame cover 101 is provided with a first limiting portion 103 and a second limiting portion 104 , which are respectively located at two ends of the upper frame cover 101 , and the first limiting portion 103 is provided with a PIN needle connecting groove 105 .

[0062] During implementation, a first limiting portion 103 and a second limiting portion 104 are respectively provided at both ends of the upper frame sleeve 101. The first limiting portion 103 and the second limiting portion 104 play a role in limiting the enameled wire after winding. When the stator structure provided in the present application is installed in an outer rotor motor, the outer rotor motor has a PCB board, and a PIN pin is usually provided on the PCB board. The PIN pin is used to be electrically connected to the stator structure. A PIN pin connecting groove 105 is provided on the first limiting portion 103, and the PIN pin connecting groove 105 is connected to the PIN pin.

[0063] In some embodiments, the lower frame cover 102 is provided with a third limiting portion 106 and a fourth limiting portion 107 , the third limiting portion 106 and the fourth limiting portion 107 are respectively located at two ends of the upper frame cover 101 , and the third limiting portion 106 is provided with a PIN needle connecting groove 105 .

[0064] During implementation, a third limiting portion 106 and a fourth limiting portion 107 are respectively provided at both ends of the lower frame sleeve 102, and the third limiting portion 106 and the fourth limiting portion 107 play a role in limiting the wound enameled wire.

[0065] The present invention also provides an outer rotor motor, characterized in that it includes: the rolled stator structure mentioned in the above embodiment, the detailed structure of which has been described in the above embodiment. No further details will be given here, but it should be noted that: the spliced ​​stator structure 1 described in the embodiment of the present invention is applied to an outer rotor motor.

[0066] The present invention also provides a method for manufacturing a rolled stator structure, which is used to manufacture the rolled stator structure mentioned in the above embodiment, comprising the following steps:

[0067] S1, punching and riveting, forming a plurality of iron cores 2 by punching and riveting the silicon steel sheets, and connecting adjacent iron cores 2 by connecting bridges 204;

[0068] S2, winding, placing multiple cores 2 into a bobbin 1 and winding enameled wire around the bobbin 1 to form a winding 3;

[0069] S3, rolling up, using a tool to roll up the iron core 2 having the winding 3 after winding;

[0070] S4, welding, after rolling, the boot portion 203 of the first core 2 is butted with the boot portion 203 of the last core 2 according to the arrangement order, and the boot portion 203 of the first core 2 is connected and fixed to each other by welding;

[0071] S5, plastic coating, coating the rolled iron core 2 with BMC to form an integral body of the iron core 2 and the winding 3;

[0072] S6, turning, turning the entire outer circle after plastic coating to remove the connecting bridge 204 on the outer periphery of the iron core 2.

[0073] During implementation, the iron core 2 is stamped and riveted into shape by a mold to form a plurality of iron cores 2, with a connecting bridge 204 between adjacent iron cores 2, the boot 203 of the iron core 2 and the connecting bridge 204 being integrally formed, the iron core 2 is installed in the bobbin 1, and the enameled wire is wound on the bobbin 1 by a winding device to form a winding 3 on the bobbin 1. At this time, the spacing between adjacent iron cores 2 is large, the difficulty of winding equipment in winding is low, the winding efficiency is high, and because the difficulty of winding is reduced, the achievable slot full rate can be increased accordingly. After winding, the iron core 2 is rolled up through work, and the yoke 202 of the iron core 2 after rolling up is butted against each other through a butt joint structure, and the boot 203 of the iron core 2 has a connecting structure. The connecting bridge 204 and the boot portion 203 of the core 2 are always kept at a predetermined spacing during the rolling process. Finally, multiple cores 2 are wound into a circular stator structure by the tooling. After rolling, the boot portion 203 of the first core 2 is connected to the boot portion 203 of the last core 2 in the arrangement order, and the boot portion 203 of the first core 2 and the boot portion 203 of the last core 2 are connected and fixed to each other by welding; the stator structure after rolling is subjected to BMC plastic coating treatment to form an integral structure of the core 2 and the winding 3 and to form a shell 4 on the outside of the core and the sleeve, and the outer circle part of the integral structure is turned. The purpose of the turning process is to remove the connecting bridge 204 on the periphery of the core 2, so as to finally obtain a rolled stator structure.

[0074] The above is a specific description of the preferred implementation of the present invention, but the invention is not limited to the embodiments. Those skilled in the art can make various equivalent modifications or substitutions without violating the spirit of the present invention. These equivalent modifications or substitutions are all included in the scope defined by the claims of this application.

Claims

1. A rolled stator structure, characterized in that: include: Wire rack; A plurality of iron cores are installed in a bobbin and are provided with a tooth portion, a yoke portion is provided at one end of the tooth portion, a boot portion is provided at the other end of the tooth portion, a butt joint structure is provided on the tooth portion, the yoke portions of two adjacent iron cores are butt jointed with each other through the butt joint structure, and the boot portions of two adjacent iron cores are connected through a connecting bridge.

2. The rolled stator structure according to claim 1, characterized in that: The butt joint structure comprises a mortise and a tenon, the mortise and the tenon are respectively arranged on both sides of the yoke, and the yokes of two adjacent iron cores are butt jointed through the tenon and the mortise.

3. The rolled stator structure according to claim 1, characterized in that: The plurality of iron cores are arranged in sequence, and the boot portion of the first iron core and the boot portion of the last iron core in the arrangement sequence are welded and fixed.

4. The rolled stator structure according to claim 1, characterized in that: The thickness of the connecting bridge is 0.3-1 mm.

5. The rolled stator structure according to claim 1, characterized in that: There is a notch between two adjacent shoe parts, and the width of the notch is 0-2mm.

6. The rolled stator structure according to claim 1, characterized in that: The wire rack comprises an upper frame sleeve and a lower frame sleeve, the upper frame sleeve is butted against the lower frame sleeve, an accommodating cavity is formed between the upper frame sleeve and the lower frame sleeve, and the tooth portion is located in the accommodating cavity.

7. The rolled stator structure according to claim 6, characterized in that: The upper frame sleeve is provided with a first limiting portion and a second limiting portion, the first limiting portion and the second limiting portion are respectively located at two ends of the upper frame sleeve, and the first limiting portion is provided with a PIN needle connecting groove.

8. The rolled stator structure according to claim 6, characterized in that: The lower frame sleeve is provided with a third limiting portion and a fourth limiting portion, and the third limiting portion and the fourth limiting portion are respectively located at two ends of the upper frame sleeve.

9. An outer rotor motor, characterized in that: include: The rolled stator structure according to any one of claims 1 to 8.

10. A method for manufacturing the rolled stator structure according to any one of claims 1 to 8, characterized in that: The following steps are involved: Stamping and riveting: Silicon steel sheets are processed by stamping and riveting to form multiple iron cores, and adjacent iron cores are connected by connecting bridges; Winding, placing multiple cores into a bobbin and winding enameled wire around the bobbin to form a winding; Rolling, rolling the iron core with winding after winding by tooling; Welding: After rolling, the boot of the first core is butted against the boot of the last core in the order of arrangement, and the boot of the first core is connected and fixed to the boot of the last core by welding; Plastic coating: plastic coating the rolled core BMC to form a whole with the core and winding; Turning: Turn the entire outer circle after plastic coating to remove the connecting bridge on the periphery of the core.

Images