Stator winding method, adjusting device and manufacturing method of motor

Abstract

The invention provides a stator winding method, an adjusting device and a manufacturing method of a motor, and belongs to the field of compressor casting, and the method comprises the steps: before a coil of a block stator in a same-phase winding is wound to a block stator of another subarea, a transition line between two subareas is rotatably wound on at least one adjusting rod, and the transition line is wound on the adjusting rod; the adjusting rod can rotate along the axis of the adjusting rod so as to loosen or tighten the transition line. According to the invention, one or more adjusting rods are arranged between different coils, so that the tightness of the transition line can be adjusted timely, and the coils are prevented from being snapped due to too large tension of the transition line when being connected with the transition line. And the transition line cannot be separated from the preset position due to too small tension, so that the safety problem can be avoided. The transition wire can be adjusted to stretch out and draw back through the adjusting rod, so that the tightening degree of the transition wire can be adjusted in time, the requirement for the accuracy of the length of the transition wire and the matching performance of the transition wire and the winding support is not high, and the yield of manufactured stators is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of compressors, and particularly relates to a stator winding method, an adjusting device, and a manufacturing method of an electric motor. Background Art

[0002] The segmented electric motor has the advantages of high slot fill factor, high material utilization rate, high efficiency, etc., and has become one of the development directions of high-efficiency electric motors. However, due to excessive segmentation of the motor, the connection of the transition lines is cumbersome. At present, there are mainly two connection methods for the transition lines of the segmented electric motor of the compressor. The first wiring method is that the phase windings in the stator are connected separately after the circle is completed, and the two-phase windings are connected by plug terminals. The disadvantages of this method are numerous joints, poor reliability, low production efficiency, and high cost. Refer Figure 1 to the second connection method shown in the figure. A plurality of coils in each phase winding are sequentially connected in series by means of a circuitous interspersed transition line, but this connection method also has many disadvantages: ① The S-shaped wire routing of the winding machine is complex, reducing the production efficiency; ② The winding brackets at both ends of the iron core are designed complexly due to considering the S-shaped movement, and are difficult to manufacture; ③ The transition line does not have a telescopic function, and has high requirements for the accuracy of the length of the transition line and its compatibility with the winding bracket, which easily leads to a low yield rate.

[0003] Therefore, when the traditional segmented electric motor is manufactured and produced, there are defects such as a large number of joints, poor reliability, low production efficiency, and low yield rate.

[0004] It should be noted that the information disclosed in the background art part of the present invention is only intended to deepen the understanding of the general background art of the present invention, and should not be regarded as an admission or any form of suggestion that this information constitutes the prior art known to those skilled in the art. Summary of the Invention

[0005] The purpose of the present invention is to provide a stator winding method, an adjusting device, and a manufacturing method of an electric motor, so as to solve the technical problems of a large number of joints, poor reliability, low production efficiency, and low yield rate existing in the manufacturing and production of traditional segmented electric motors.

[0006] To solve the above technical problems, the present invention provides a stator winding method. The stator includes a plurality of segmented stators and coils wound around the segmented stators. The plurality of segmented stators are divided into a plurality of zones along the circumferential direction of the stator. Each zone includes a plurality of segmented stators wound with coils. Coils with the same arrangement order in different zones are connected as the same phase winding. The method is characterized by including:

[0007] Before the coil of one segmented stator in the same phase winding is wound around the segmented stator in another zone, the transition line between the two zones is wound around at least one adjusting rod, and the adjusting rod can rotate along its own axis to relax or tighten the transition line.

[0008] Preferably, the adjusting rod has a certain resilient torque when rotating.

[0009] Preferably, the movement of the adjusting rod along the axis enables the transition line to be clamped in or withdrawn from the transition line.

[0010] Based on the same inventive concept, the present invention also provides a stator winding adjusting device for the above-mentioned stator winding method. The stator winding adjusting device includes an adjusting rod, and the adjusting rod has a bifurcated structure for the transition line to pass through. The transition line passes through the bifurcated structure and rotates and winds.

[0011] Preferably, the adjusting rod includes:

[0012] An adjusting base;

[0013] An adjusting part, the adjusting part includes at least two fork rods. The first ends of the fork rods are connected to the adjusting base, and the second ends of the fork rods are distributed at intervals to form a bifurcated structure for the transition line to pass through.

[0014] Preferably, the size of the adjusting part gradually decreases from the first end to the second end.

[0015] Preferably, the outer shape of the adjusting part is a cone.

[0016] Preferably, the adjusting rod includes an adjusting base and an adjusting part. The adjusting part is in a sleeve form, and the end of the sleeve forms the bifurcated structure for the transition line to pass through. The adjusting base is detachably inserted into the sleeve to change the opening size of the bifurcated structure.

[0017] Preferably, the size of the adjusting base gradually decreases along the insertion direction, or the internal size of the adjusting part gradually decreases.

[0018] Preferably, a torsion spring is provided on the adjusting rod.

[0019] Preferably, the stator winding adjusting device further includes:

[0020] A sensor device for detecting the tightness of the transition line and outputting a detection signal;

[0021] A control unit, connected to the sensor device, for receiving the detection signal and outputting a control signal;

[0022] A driving unit for receiving the control signal and driving the adjusting base to rotate;

[0023] A lifting unit for receiving the control signal and driving the adjusting base to move along its longitudinal direction;

[0024] An external power supply is electrically connected to the driving unit, the sensor device and the control unit.

[0025] Based on the same inventive concept, the present invention also provides a method for manufacturing a motor, comprising:

[0026] The stator winding method as described above;

[0027] After the stator winding is completed, a plurality of the segmented stators are spliced ​​into a full-circle motor, and the adjustment rod can rotate along its own axis to loosen or tighten the transition wire;

[0028] After the splicing is completed, the adjusting rod is moved along the axis to withdraw from the transition line.

[0029] Preferably, the transition line after the adjustment rod is withdrawn is hooked and pulled toward the center of the motor to tighten it.

[0030] Compared with the prior art, the stator winding method of the present invention has the following advantages:

[0031] The present invention is that before the coil of a segmented stator in the same phase winding is wound to the segmented stator of another segmented stator, the transition wire between the two segments is rotated and wound on at least one adjusting rod, and the adjusting rod can loosen or tighten the transition wire along its own axis. Therefore, the stator winding method provided by the present invention can adjust the tightness of the transition wire in time by setting one or more adjusting rods between different coils in different segments when connecting the transition wire, so as to ensure that the coil will not be broken due to excessive tension of the transition wire when connecting the transition wire. It will not be separated from the preset position due to too small tension of the transition wire, so as to avoid safety and regulatory issues. And after the segmented motor is fixed in a circle, the adjusting rod is withdrawn from the transition wire, and the transition wire can still maintain its original state, so that too many joints can be avoided, and the transition wire does not need to be interlaced back and forth, and the coil bracket can be designed to be simple, reducing the complexity of the bracket mold and reducing the manufacturing difficulty. The transition wire can be adjusted and retracted by the adjusting rod, so that the tension of the transition wire can be adjusted in time, and the accuracy of the length of the transition wire and its compatibility with the winding bracket are not required to be high, so as to improve the yield rate of the stator manufacturing.

[0032] For block motors, the transition wires between different coils of the same-phase winding and the coils on both sides are the same unbroken enameled wire, with no joints between them, so as to achieve the purpose of reducing the number of stator terminals. The transition wire runs on the outside of the stator and is tightened in real time under the action of the adjustment rod to avoid leaving its designed position and prevent safety and regulatory issues. When the distance between the two coils connected by the transition wire changes, the adjustment rod can be adjusted in time. The adjustment rod has a bifurcated structure for the transition wire to pass through. The transition wire passes through the bifurcated structure. The adjustment rod can be rotated to wind and tighten the transition wire, and reverse rotation can loosen it, so that the transition wire remains straight.

[0033] The manufacturing method of the motor provided by the present invention and the stator winding method provided by the present invention belong to the same inventive concept. Since the manufacturing method of the motor provided by the present invention includes the above-mentioned stator winding method, therefore, the manufacturing method of the motor provided by the present invention can also reduce the number of stator joints, reduce the production cost and manufacturing difficulty of the motor, ensure the stable and reliable operation of the motor, with outstanding quality, and improve the yield of motor production and manufacturing. Description of the Drawings

[0034] Figure 1 is a schematic diagram of the wiring method of the transition wire in an embodiment;

[0035] Figure 2 is a perspective view of the adjusting rod in an embodiment of the present invention;

[0036] Figure 3 is to pass the transition wire through Figure 2 the adjusting rod in;

[0037] Figure 4 is Figure 2 the structural schematic diagram after the adjusting rod in winds the transition wire;

[0038] Figure 5 is a perspective view of the adjusting rod in another embodiment of the present invention;

[0039] Figure 6 is Figure 5 the structural schematic diagram of the adjusting base included in the adjusting rod in;

[0040] Figure 7 is Figure 5 the cross-sectional view of the adjusting rod in;

[0041] Figure 8 is to pass the transition wire through Figure 5 the adjusting rod in;

[0042] Figure 9 is Figure 5 the structural schematic diagram after the adjusting rod in winds the transition wire;

[0043] Figure 10 is a structural schematic diagram of the control system in an embodiment of the present invention;

[0044] Figure 11 is a partial schematic diagram of the wiring method of the transition wire between coils in an embodiment of the present invention;

[0045] Figure 12 is Figure 11 the planar structural schematic diagram of the wiring method of the transition wire between coils in;

[0046] Figure 13 It is a schematic diagram of the connection structure between the bracket and the transition line in an embodiment of the present invention;

[0047] Figure 14 is Figure 13 Another perspective schematic diagram of the connection structure between the middle bracket and the transition line;

[0048] Figure 15 It is a schematic diagram of the structure of the stator in an embodiment of the present invention;

[0049] In the figure,

[0050] 100 - Coil; 110 - Bracket;

[0051] 120 - Perforation; 200 - Transition line;

[0052] 300 - Adjusting rod; 310 - Adjusting base;

[0053] 311 - Fixing part; 312 - Connecting part;

[0054] 320 - Adjusting part; 321 - First end;

[0055] 322 - Second end; 400 - Control system;

[0056] 410 - Control unit; 420 - Sensor device;

[0057] 430 - Driving unit; 440 - External power supply;

[0058] 450 - Lifting unit; 500 - Segmented stator. Detailed implementation manners

[0059] To make the objectives, advantages and features of the present invention clearer, the following further elaborates in detail on the stator winding method, adjusting device and motor manufacturing method proposed by the present invention in conjunction with the accompanying drawings and specific embodiments. It should be noted that the accompanying drawings are all in very simplified forms and use non - precise scales, only for conveniently and clearly assisting in explaining the objectives of the embodiments of the present invention. It should be understood that the drawings in the specification do not necessarily show the specific structure of the present invention in proportion, and the illustrative features used to explain certain principles of the present invention in the drawings of the specification will also adopt a slightly simplified drawing method. The specific design features disclosed herein, such as specific dimensions, directions, positions and shapes, will be partially determined by the specific application and usage environment. Also, in the following described embodiments, sometimes the same reference numerals are used commonly between different drawings to represent the same part or parts having the same function, and the repeated description thereof is omitted. In this specification, similar reference numerals and letters are used to represent similar items. Therefore, once an item is defined in one drawing, it does not need to be further discussed in subsequent drawings.

[0060] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include at least one of such features. In the description of the present invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise specifically defined.

[0061] In the description of this specification, the description with reference to terms such as "one embodiment", "some embodiments", "example", "specific example", or "some examples" means that the specific features, structures, materials, or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described can be combined in a suitable manner in any one or more embodiments or examples. In addition, without contradiction, those skilled in the art can combine and combine the different embodiments or examples described in this specification and the features of different embodiments or examples.

[0062] Refer to Figures 2 to 15 A specific implementation of a stator winding method disclosed. The stator includes a plurality of segmented stators 500, and coils 100 wound around the segmented stators. The plurality of segmented stators 500 are divided into a plurality of zones along the circumferential direction of the stator. Each zone includes a plurality of segmented stators 500 wound with coils 100. Coils 100 with the same arrangement order in different zones are connected as the same phase winding, including: before the coils 100 of one of the segmented stators 500 in the same phase winding are wound around the segmented stator 500 in another zone, the transition line 200 between the two zones is wound around at least one adjusting rod 300, and the adjusting rod 300 can rotate along its own axis (i.e., the dashed line a in Figure 3 to loosen or tighten the transition line 200.

[0063] When wiring the transition line 200 of a traditional segmented motor, one way is to connect by plug terminals between two windings. The disadvantages of this method are numerous joints, poor reliability, low production efficiency, and high cost. Refer to Figure 1 The second connection method shown in Figure 1In the wiring method shown, multiple coils 100 in each phase winding are connected in series in a circuitous and interlaced manner through transition lines 200, wherein the multiple coils 100 include three groups of phase windings, and the three phase windings are represented by letters U, V, and W respectively. And each phase winding includes four coils 100. However, this connection method also has many disadvantages: ① The S-shaped routing of the winding machine is complicated, which reduces production efficiency; ② The winding brackets 110 at both ends of the iron core are complex in design and difficult to manufacture because of the need to consider the S-shaped routing; ③ The transition line does not have a telescopic function, and the accuracy of the transition line length and its compatibility with the winding bracket 110 are required to be high, which easily leads to low yield.

[0064] However, the stator winding method provided in this embodiment is that before the coil 100 of one segmented stator 500 in the same phase winding is wound to the segmented stator 500 of another segmented stator, the transition wire 200 between the two segments is rotatably wound on at least one adjusting rod 300, and the adjusting rod 300 can be rotated along its own axis (i.e., Figure 3 The middle dotted line a) loosens or tightens the transition line 200, which can adjust the tightness of the transition line 200 in time, ensuring that the coil 100 will not be broken due to excessive tension of the transition line 200 when connecting the transition line 200. It will not be out of the preset position due to too little tension of the transition line 200, thereby avoiding safety and regulatory issues. After the block motor is assembled and fixed, the adjustment rod 300 is withdrawn from the transition line 200, and the transition line 200 can still maintain its original state, which can avoid too many joints, and the transition line 200 does not need to be inserted back and forth, and the bracket 110 of the coil 100 can be designed to be simple, reducing the complexity of the bracket 110 mold and reducing the manufacturing difficulty. The transition line 200 can be adjusted and retracted by adjusting the rod 300, so that the tension of the transition line 200 can be adjusted in time, and the accuracy of the length of the transition line 200 and its compatibility with the winding bracket are not required to be high, thereby improving the yield rate of the stator manufacturing.

[0065] For the block motor, the transition wire 200 between different coils 100 of the same-phase winding and the coils 100 on both sides are the same unbroken enameled wire, without joints between them, and are integrated to achieve the purpose of reducing the entire stator terminal. The transition wire 200 runs on the outside of the stator, and the adjustment rod 300 has a certain rebound torque when rotating. Under the action of the adjustment rod 300, the transition wire 200 can be tightened in real time to avoid leaving its designed position and prevent safety and regulatory issues. When the distance between the two coils 100 connected by the transition wire 200 changes, the adjustment rod 300 can be adjusted in time. The adjustment rod 300 has a bifurcated structure 320 for the transition wire 200 to pass through. The transition wire 200 passes through the bifurcated structure 320. The adjustment rod 300 rotates to make the transition wire 200 wind and tighten, and the reverse rotation can loosen it, so that the transition wire 200 remains in a straight state.

[0066] Specifically, refer toFigure 11 , Figure 12 , and Figure 15 As shown, the segmented motor includes 12 segmented stators 500, and each segmented stator 500 is wound with a coil 100. The 12 segmented stators 500 are divided into 3 zones along the circumferential direction of the stator. In each zone, the coils 100 with the same arrangement order are connected as the same phase winding. In an actual segmented motor, there are three windings, and the three phase windings are represented by the letters U, V, and W respectively. There are four coils 100 in each phase winding. The coils 100 are connected by transition lines 200.

[0067] Among them, before the coil 100 of one of the segmented stators 500 in the same phase winding is wound to the segmented stator 500 in another zone, the transition line 200 between the two zones is wound around at least one adjusting rod 300, and the adjusting rod 300 can rotate along its own axis (i.e., Figure 3 the dashed line a in ) to relax or tighten the transition line 200. For example, among the four coils 100 in the U-phase winding, one or more adjusting rods 300 can be provided between the first coil 100 and the second coil 100, or between the second coil 100 and the third coil 100, or between the third coil 100 and the fourth coil 100. The adjusting rod 300 moves along the axis (i.e., Figure 3 the dashed line a in ) to make the transition line 200 snap in. Then, by rotating the adjusting rod 300, the transition line 200 can be wound around the adjusting rod 300. After winding, the four coils 100 of the U-phase winding are connected in series through the transition line 200. And in the same phase winding, the transition lines 200 between different coils 100 are not disconnected to reduce the joints of the transition lines 200. The transition lines 200 between different coils 100 in the same phase winding and the coils 100 on both sides are the same unbroken enameled wire without joints and are integrated. By moving the adjusting rod 300 along the axis (i.e., Figure 3 the dashed line a in ) in the direction opposite to when the transition line 200 is snapped in, the adjusting rod 300 can be withdrawn from the transition line 200. The same method as above is also used for the four coils 100 in other phase windings to be connected in series through the transition line 200 to achieve the purpose of reducing the wiring joints of the entire stator. The transition line 200 runs outside the stator and is tightened in real time under the action of the adjusting rod 300 to avoid leaving its designed position and prevent safety and compliance problems.

[0068] The present invention also discloses a stator winding device for the above stator winding method. The stator winding device includes an adjusting rod 300, and the adjusting rod 300 has a bifurcated structure for the transition line 200 to pass through. The transition line 200 passes through the bifurcated structure and rotates and winds.

[0069] Exemplarily, the adjusting rod 300 includes: an adjusting base 310; an adjusting portion 320, the adjusting portion 320 includes at least two fork rods (not labeled in the figure), a first end 321 of the fork rod is connected to the adjusting base 310, and a second end 322 of the fork rod is spaced apart to form a bifurcated structure for the transition line 200 to pass through.

[0070] As one of the embodiments, the first end 321 of the fork rod is fixedly connected to the adjusting base 310. The adjusting rod 300 is provided with a torsion spring (not shown in the figure). One end of the torsion spring is connected to the adjusting rod 300, and the other end is fixed to a certain fixed body so that the adjusting rod 300 has a certain return torque when rotating. The size of the adjusting portion 320 gradually decreases from the first end 321 to the second end 322.

[0071] Specifically, referring Figures 2 to 4 As shown, wherein, the transition line 200 can be wound and deformed along with the rotation of the adjusting rod 300 in the axial direction. The outer shape of the adjusting base 310 can be a conical structure, a cuboid structure, etc. In this embodiment, there are no specific requirements for the shape and size of the adjusting base 310. The adjusting portion 320 can be a conical structure, a cylindrical structure, an elliptical cylindrical structure, or even other special-shaped cylinders, as long as the size of the adjusting portion 320 gradually decreases from the first end 321 to the second end 322, so as to facilitate the detaching of the transition line 200 from the adjusting portion 320. That is, along the axis direction of the adjusting rod 300, the size of the adjusting portion 320 gradually decreases along the exit direction of the adjusting rod 300, ensuring that the adjusting rod 300 can smoothly exit when it needs to exit from the transition line 200. In this embodiment, preferably, the outer shape of the adjusting portion 320 is a conical structure. In addition, the adjusting base 310 and the fork rod can be fixedly connected or detachably connected. The two fork rods can be symmetrically distributed on the top of the adjusting base 310 or arbitrarily distributed on the top of the adjusting base 310. Here, no limitation is made. Preferably, the two fork rods are symmetrically distributed on the top of the adjusting base 310 to form a bifurcated structure.

[0072] During use, the adjusting rod 300 moves along the axis to make the transition line 200 snap in, pass the transition line 200 through the bifurcated structure, that is, pass the transition line 200 through the middle of the adjusting portion 320, and then drive the adjusting base 310 to make the adjusting base 310 rotate clockwise (that is, looking down at the adjusting rod 300 from the top, along the Figure 3 dotted line a in the figure) (that is, looking down at the adjusting rod 300 from the top, along the direction shown by the arrow b in the Figure 3 figure) or counterclockwise (that is, looking down at the adjusting rod 300 from the top, along the direction opposite to Figure 3Rotate in the opposite direction shown by arrow b in the figure) to wind the transition line 200 around the adjusting part 320. When the tension of the transition line 200 is too large, the adjusting base 310 can be rotated in the opposite direction to the winding direction. When the tension of the transition line 200 is too small, the adjusting base 310 can be rotated in the same direction as the winding direction, so that the tension of the transition line 200 is neither too large nor too small, realizing the tension adjustment of the transition line 200, making it always maintain an appropriate length, ensuring that the transition line 200 is tightened in its correct position, and ensuring the improvement of the yield rate. The adjusting rod 300 has the property of being easy to withdraw the transition line 200.

[0073] It should be noted that the adjusting rod 300 can not only rotate in the clockwise or counterclockwise direction along its axis, but also move along its axis or perpendicular to the axis, or a combined movement of rotation and movement. As long as the transition line 200 can be wound around the adjusting rod 300, and the transition line 200 can be tightened by rotating in the same direction as the winding direction of the transition line 200, and the transition line 200 can be relaxed by rotating in the opposite direction to the winding direction of the transition line 200. So that the tension of the transition line 200 is neither too large nor too small, realizing the tension adjustment of the transition line 200, making it always maintain an appropriate length, ensuring that the transition line 200 is tightened in its correct position, and ensuring the improvement of the yield rate.

[0074] Furthermore, the adjusting rod 300 further includes a control system 400. The control system 400 includes: a sensor device 420, connected to the transition line 200, for detecting the tension of the transition line 200 and outputting a detection signal; a control unit 410, connected to the sensor device 420, for receiving the detection signal and outputting a control signal; a driving unit 430, for receiving the control signal and driving the adjusting base 310 to rotate; a lifting unit 450, for receiving the control signal and driving the adjusting base 310 to move along its longitudinal direction (i.e., Figure 3 the direction where the dotted line a is located in the figure) to move; an external power supply 440, electrically connected to the driving unit 430, the sensor device 420 and the control unit 410.

[0075] Specifically, refer to Figures 2 to 4 and Figure 10As shown, in order to achieve the automated production of the segmented motor, the adjusting rod 300 is further provided with a control system 400. In this embodiment, the sensor device 420 can be a tension sensor, or a torsion sensor of the adjusting rod 300, etc., which are some sensor devices 420 that can detect the tension of the transition line 200 and output a detection signal. Among them, the sensor device 420 is movably connected to the transition line 200. When the transition line 200 is tensioned, the tension of the tensioned transition line 200 can be transmitted to the sensor device 420 and output a detection signal to the control unit 410. The control unit 410 can be a controller, a single-chip microcomputer, etc. The control unit 410 receives the detection signal output by the sensor device 420 and outputs a control signal. The driving unit 430 can be a driving device such as a servo motor. The driving unit 430 can be connected to the adjusting base 310 to drive the adjusting base 310 and the adjusting part 320 to rotate and wind, so that the transition line 200 can be wound around the adjusting rod 300. At the same time, the driving unit 430 can receive the control signal output by the control unit 410 and drive the adjusting base 310 to rotate counterclockwise or clockwise to tension or relax the transition line 200, so that it always maintains an appropriate length and ensures that the transition line 200 is tightened in its correct position. The lifting unit 450 can be a lifting cylinder, a linear reciprocating motion device, etc. In this embodiment, the lifting unit 450 can be connected to the adjusting base 310 to drive the adjusting base 310 to move in its longitudinal direction, so that the adjusting rod 300 can be withdrawn from the transition line 200. In addition, for the control methods of the control unit 410 with the driving unit 430 and the lifting unit 450, it can be either communication connection control or electrical connection control. Here, no requirements are made as long as the control unit 410 can control the driving unit 430 and the lifting unit 450.

[0076] As another embodiment thereof, the adjusting rod 300 includes an adjusting base 310 and an adjusting part 320. The adjusting part 320 is in the form of a sleeve. The end of the sleeve forms the bifurcated structure for the transition line 200 to pass through. The sleeve is an expansion tube. The adjusting base 310 is detachably inserted into the sleeve to change the opening size of the bifurcated structure.

[0077] Specifically, refer to Figures 5 to 10As shown, the adjusting part 320 includes several U-shaped rods. The opening parts of adjacent U-shaped rods are connected to each other and enclose to form a sleeve, and the closed ends are distributed at intervals to form a bifurcated structure. The adjusting rod 300 is provided with a torsion spring. One end of the torsion spring is connected to the adjusting rod 300, and the other end is fixed on a certain fixed body, so as to have a certain resilience torque when the adjusting rod 300 rotates. The adjusting base 310 may include a fixing part 311 and a connecting part 312. The fixing part 311 is configured as a cylindrical shape, a conical shape or other structures for fixing on a certain fixed body. Of course, the adjusting base 310 may also be configured as a frustum structure. The size of the adjusting base 310 gradually decreases along the insertion direction, or the internal size of the adjusting part 320 gradually decreases. On the one hand, when the adjusting part 320 slides up and down along the connecting part 312, the diameter size of the entire adjusting rod 300 can be adjusted, so that the tightness of the winding of the transition line 200 can be adjusted. At this time, without rotating the fixing part 311, the transition line 200 can be tensioned or relaxed, realizing the tightness adjustment of the transition line 200, so that it always maintains an appropriate length, ensuring that the transition line 200 is tightened in its correct position and ensuring the improvement of the yield rate. On the other hand, the diameter of the top of the connecting part 312 is smaller than that of the bottom, and the size of the bifurcated structure gradually increases along the exit direction of the adjusting rod 300, ensuring that the adjusting rod 300 can smoothly exit from the transition line 200. Before the adjusting rod 300 needs to be withdrawn, the bifurcated structure adjusts the tightness of the transition line 200 in a state of expanding along the circumferential direction of the adjusting rod 300. When the tightness task of the transition line 200 is completed and the adjusting rod 300 needs to be withdrawn, the bifurcated structure is adjusted to a state of shrinking along the circumferential direction of the adjusting rod 300 to facilitate withdrawal along the axis of the adjusting rod 300.

[0078] As a reasonable deformation of this embodiment, the size of the adjusting part 320 can also gradually decrease from bottom to top. That is, in this embodiment, the adjusting part 320 can also be a conical structure. When the adjusting part 320 slides up and down along the connecting part 312, the diameter size of the entire adjusting rod 300 can be adjusted, so that the tightness of the winding of the transition line 200 can be adjusted. At this time, without rotating the fixing part 311, the transition line 200 can be tensioned or relaxed, realizing the tightness adjustment of the transition line 200, so that it always maintains an appropriate length, ensuring that the transition line 200 is tightened in its correct position and ensuring the improvement of the yield rate. On the other hand, the diameter of the top of the connecting part 312 is smaller than that of the bottom, and the size of the bifurcated structure gradually increases along the exit direction of the adjusting rod 300, ensuring that the adjusting rod 300 can smoothly exit from the transition line 200. Before the adjusting rod 300 needs to be withdrawn, the bifurcated structure adjusts the tightness of the transition line 200 in a state of expanding along the circumferential direction of the adjusting rod 300. When the tightness task of the transition line 200 is completed and the adjusting rod 300 needs to be withdrawn, the bifurcated structure is adjusted to a state of shrinking along the circumferential direction of the adjusting rod 300 to facilitate withdrawal along the axis of the adjusting rod 300.

[0079] In use, the adjustment rod 300 can be moved along the axis to engage the transition line 200. First, the transition line 200 is passed through the bifurcated structure, that is, the transition line 200 passes through the middle of the adjustment portion 320, and then along Figure 8 the direction indicated by the arrow c in Figure 8 , the adjustment portion 320 is rotated, and the transition line 200 can be wound around the adjustment rod 300. Then, the fixing portion 311 is fixed to the fixed body, and the adjustment portion 320 is pushed up and down, and the transition line 200 can be tensioned or relaxed, realizing the tension adjustment of the transition line 200, so that it always maintains an appropriate length, ensuring that the transition line 200 is tightened in its correct position and ensuring the improvement of the yield rate.

[0080] Furthermore, in this embodiment, a control system 400 can also be provided to realize the automatic control of tensioning or relaxing the transition line 200 or rotating and winding the transition line 200. The control system 400 includes: a sensor component 420, connected to the transition line 200, for detecting the tightness of the transition line 200 and outputting a detection signal; a control unit 410, connected to the sensor component 420, for receiving the detection signal and outputting a control signal; a driving unit 430, for receiving the control signal and driving the adjustment base 310 to rotate; a lifting unit 450, for receiving the control signal and driving the adjustment base 310 to move along its longitudinal direction (that is, Figure 3 the direction where the dashed line a is located in Figure 3 ); an external power supply 440, electrically connected to the driving unit 430, the sensor component 420, and the control unit 410.

[0081] Specifically, referring to Figures 5 to 10As shown, the sensor device 420 can be a tension sensor, or a torque sensor of the adjusting rod 300, etc., which are some sensor devices 420 that can detect the tension of the transition line 200 and output a detection signal. Among them, the sensor device 420 is movably connected to the transition line 200. When the transition line 200 is tensioned, the tension that tensions the transition line 200 can be transmitted to the sensor device 420 and a detection signal is output to the control unit 410. The control unit 410 can be a controller, a single-chip microcomputer, etc. The control unit 410 receives the detection signal output by the sensor device 420 and outputs a control signal. The driving unit 430 can be a driving device such as a servo motor. The function of the driving unit 430 here is somewhat different from that of the driving unit 430 in the above embodiment. In this embodiment, the driving unit 430 can be connected to the adjusting base 310 to drive the adjusting base 310 and the adjusting part 320 to rotate and wind, so that the transition line 200 can be wound around the adjusting rod 300. Therefore, the function of the driving unit 430 here is only to rotate and wind the transition line 200 around the adjusting rod 300 and is not used to adjust the tightness of the transition line 200. The lifting unit 450 can be a lifting cylinder, a linear reciprocating motion device, etc. In this embodiment, the lifting unit 450 can be connected to the adjusting part 320. On the one hand, the lifting unit 450 pushes the adjusting part 320 to move along the longitudinal direction of the adjusting rod 300. Since the diameter of the adjusting base 310 gradually decreases from bottom to top, the transition line 200 can be tensioned or relaxed, realizing the adjustment of the tightness of the transition line 200, so that it always maintains an appropriate length, ensuring that the transition line 200 is tightened in its correct position and ensuring the improvement of the yield rate. On the other hand, the lifting unit 450 pushes the adjusting part 320 to move along the longitudinal direction of the adjusting rod 300, and the adjusting rod 300 can be withdrawn from the transition line 200. In addition, for the control methods of the control unit 410 with the driving unit 430 and the lifting unit 450, it can be either communication connection control or electrical connection control. Here, there is no requirement as long as the control unit 410 can control the driving unit 430 and the lifting unit 450.

[0082] In this embodiment, since the bifurcated structure is designed to be pre-expanded, and the pre-expanded shape can first contract before exiting along the axis. Therefore, when the adjusting rod 300 is withdrawn from the transition line 200, the transition line 200 can be maintained in its previous state, that is, when the adjusting rod 300 is withdrawn, it will not affect the transition line 200.

[0083] In addition, in this embodiment, the driving unit 430 can also be connected to the adjustment base 310. When the driving unit 430 receives the control signal output by the control unit 410, it drives the adjustment base 310 to move up and down to tighten or loosen the transition line 200, so as to adjust the tension of the transition line 200, so that it always maintains a suitable length, ensures that the transition line 200 is tightened in its correct position, and ensures the improvement of the yield rate. In order to facilitate the withdrawal of the adjustment rod 300 from the transition line 200, preferably, the lifting unit 450 is connected to the adjustment part 320, and the adjustment base 310 includes a fixing part 311 and a connecting part 312.

[0084] In summary, in different embodiments of the application, before the coil 100 of one segmented stator 500 in the same phase winding is wound around the segmented stator 500 of another segment, the transition wire 200 between the two segments is rotatably wound on at least one adjusting rod 300, and the adjusting rod 300 can be rotated along its own axis (i.e., Figure 3 The middle dotted line a) loosens or tightens the transition line 200, which can adjust the tightness of the transition line 200 in time, ensuring that the coil 100 will not be broken due to excessive tension of the transition line 200 when connected to the transition line 200. It will not be out of the preset position due to too little tension of the transition line 200, thereby avoiding safety and regulatory issues. After the block motor is assembled and fixed, the adjustment rod 300 is withdrawn from the transition line 200, and the transition line 200 can still maintain its original state, which can avoid too many joints, and the transition line 200 does not need to be inserted back and forth, and the coil bracket 110 can be designed to be simple, reducing the complexity of the bracket 110 mold and reducing the manufacturing difficulty. The transition line 200 can be adjusted and retracted by adjusting the rod 300, so that the tension of the transition line 200 can be adjusted in time, and the accuracy of the length of the transition line 200 and its compatibility with the winding bracket are not required to be high, thereby improving the yield rate of the stator manufacturing.

[0085] For block motors, the transition wire 200 between different coils 100 of the same-phase winding is the same unbroken enameled wire as the coils on both sides, with no joints between them, so as to achieve the purpose of reducing the entire stator terminal. The transition wire runs on the outside of the stator and is tightened in real time under the action of the adjustment rod 300 to avoid leaving its designed position and prevent safety and regulatory issues. When the distance between the two coils 100 connected by the transition wire 200 changes, the adjustment rod 300 can be adjusted in time. The adjustment rod 300 has a bifurcated structure for the transition wire 200 to pass through. The transition wire 200 passes through the bifurcated structure. The adjustment rod 300 can rotate to wind and tighten the transition wire 200, and rotate in the opposite direction to loosen it, so that the transition wire 200 remains in a straight state.

[0086] This embodiment also discloses a method for manufacturing a motor, including the above-mentioned stator winding method;

[0087] After the stator winding is completed, a plurality of the segmented stators are spliced into a complete circular motor, and the adjusting rod 300 can rotate along its own axis to loosen or tighten the transition wire 200;

[0088] After the splicing is completed, the adjusting rod 300 is moved along the axis to withdraw from the transition wire 200.

[0089] The coils 100 after being connected in series are welded and fixed to form a phase winding and form a stator as shown in Figure 15 During the process of welding and fixing between the coils 100 and the coils 100, the distance between the coils 100 and the coils 100 will change, resulting in the breakage of the transition wire 100 between the coils 100 due to too much tension, or being too loose, resulting in the transition wire 200 not being able to be stuck in the wiring groove of the coil 100, further leading to a short circuit or breakdown of the circuit, and further resulting in a decrease in the yield rate during the manufacturing process of the stator. After one phase winding is completed, the coils 100 in the remaining two phase windings are fixed by splicing in the above-mentioned manner. That is, after the stator winding is completed, a plurality of segmented stators are spliced into a complete circular motor. Then, after the splicing is completed, the adjusting rod 300 is moved along the axis to withdraw from the transition wire 200. Finally, the transition wire 200 after the adjusting rod 300 is withdrawn is pulled in the direction towards the center of the motor to be tightened.

[0090] By providing the adjusting rod 300, the tightness of the transition wire 200 can be adjusted before, during, or after the segmented motor is spliced into a complete circle, so that it always maintains an appropriate length, ensuring that the transition wire 200 is tightened in its correct position, and it is easy to ensure compliance with safety regulations and improve the yield rate. Since the diameter of the transition wire 200 is relatively thick, the transition wire 200 after withdrawal can continue to maintain a state close to a straight line. Therefore, after the adjusting rod 300 is withdrawn, the transition wire 200 should not be in a large spiral shape and should be as close to a straight line as possible, which can reduce the usage amount and resistance of the transition wire 200, thereby reducing the manufacturing cost of the stator and improving the manufacturing efficiency of the stator. After all the stator segments 500 are spliced into a complete circle, the adjusting rod 300 is withdrawn from the transition wire 200, and it is necessary to ensure that the transition wire 200 is fixed reliably after withdrawal.

[0091] It should be noted that in addition to adjusting the tightness of the transition wire 200 through the adjusting rod 300 as described above, in this embodiment, the tightness of the transition wire 200 can also be adjusted in another way. Refer to Figure 13 and Figure 14 As shown, the coil 100 is provided with a bracket 110. By providing one or more through holes 120 in the bracket 110, and when connecting the transition wire 200 between the coils 100 in the same phase winding, first fold the transition wire 200 in half, and place the folded part as shown inFigure 14 It passes through the perforation 120 in the manner shown. Then, other limiting members, such as rod-shaped structural members, can be used to pass through the folded part to limit and fix the transition line 200. During the process of splicing the coil 100 into a circle, by adjusting the length of the folded part to adjust the tightness of the transition line 200, the purpose of maintaining the tension of the transition line 200 within the set range can also be achieved. Preferably, the bracket 110 is provided with one perforation 120.

[0092] The manufacturing method of the motor provided in this embodiment and the stator winding method provided in this embodiment belong to the same inventive concept. Since the manufacturing method of the motor provided in this embodiment includes the above-mentioned stator winding method, therefore, the manufacturing method of the motor provided in this embodiment can also reduce the number of stator joints, reduce the production cost and manufacturing difficulty of the motor, ensure the stability and reliability of the motor, with outstanding quality, and improve the yield of motor production and manufacturing.

[0093] In summary, the above embodiments have described in detail different configurations of the stator winding method, the adjusting device, and the manufacturing method of the motor. Of course, the above description is only a description of the preferred embodiments of the present invention, and not any limitation on the scope of the present invention. The present invention includes but is not limited to the configurations listed in the above embodiments. Those skilled in the art can draw inferences from the content of the above embodiments. Any changes and modifications made by ordinary technicians in the field of the present invention based on the above disclosure are within the protection scope of the claims.

Claims

1. A stator winding method, wherein the stator includes a plurality of segmented stators and coils wound around the segmented stators. The plurality of segmented stators are divided into a plurality of zones along the circumferential direction of the stator. Each zone includes a plurality of segmented stators wound with coils. Coils with the same arrangement order in different zones are connected as the same-phase winding. It is characterized in that, Comprising: Before the coil of one of the segmented stators in the same-phase winding is wound around the segmented stator of another partition, the transition line between the two partitions is wound around at least one adjusting rod, and the adjusting rod can rotate along its own axis to loosen or tighten the transition line.

2. The stator winding method according to claim 1, characterized in that, When the adjusting rod rotates, it has a certain return torque.

3. The stator winding method according to claim 1, wherein Moving the adjusting rod along the axis can cause the transition line to be clamped in or withdrawn from the transition line.

4. A stator winding adjusting device for the stator winding method according to claim 1, characterized in that, The stator winding adjusting device includes an adjusting rod, and the adjusting rod has a bifurcated structure for the transition line to pass through, and the transition line passes through the bifurcated structure and rotates and winds.

5. The stator winding adjusting device according to claim 4, characterized in that The adjusting rod includes: An adjusting base; An adjusting part, the adjusting part includes at least two fork rods, the first ends of the fork rods are connected to the adjusting base, and the second ends of the fork rods are distributed at intervals to form a bifurcated structure for the transition line to pass through.

6. The stator winding adjusting device according to claim 5, characterized in that The size of the adjusting part gradually decreases from the first end to the second end.

7. The stator winding adjusting device according to claim 6, characterized in that, The outer shape of the adjusting part is a cone.

8. The stator winding adjusting device according to claim 4, wherein, The adjusting rod includes an adjusting base and an adjusting part, the adjusting part is in a sleeve form, and the end of the sleeve forms the bifurcated structure for the transition line to pass through, and the adjusting base is detachably inserted into the sleeve to change the opening size of the bifurcated structure.

9. The stator winding adjustment device according to claim 8, characterized in that, The size of the adjusting base gradually decreases along the insertion direction, or the internal size of the adjusting part gradually decreases.

10. The stator winding adjustment device according to claim 4, characterized in that, The adjusting rod is provided with a torsion spring.

11. The stator winding adjusting device according to claim 5 or 8, characterized in that, The stator winding adjusting device further includes: A sensor device for detecting the tightness of the transition line and outputting a detection signal; A control unit, connected to the sensor device, for receiving the detection signal and outputting a control signal; A driving unit for receiving the control signal and driving the adjusting base to rotate; A lifting unit for receiving the control signal and driving the adjusting base to move along its longitudinal direction; An external power source, electrically connected to the driving unit, the sensor device and the control unit.

12. A manufacturing method of an electric machine, characterized in that, Comprising: The stator winding method according to claim 1; After the stator winding is completed, a plurality of the segmented stators are spliced into a complete circular motor, and the adjusting rod can rotate along its own axis to loosen or tighten the transition line; After the splicing is completed, move the adjusting rod along the axis to withdraw from the transition line.

13. The manufacturing method of the motor according to claim 12, characterized in that, Hook and pull the transition line after the adjusting rod is withdrawn towards the direction of the center of the motor to tighten it.

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