Stator assembly and motor with same

Abstract

The invention provides a stator assembly and a motor with the same, the stator assembly comprises a stator iron core and an insulation framework, the insulation framework is assembled on the stator iron core, the insulation framework comprises a plurality of wire supporting bodies, each wire supporting body corresponds to a stator yoke part, and the wire supporting bodies are distributed at intervals along the extension direction of the stator yoke part. One side, deviating from the stator teeth, of the wire supporting body is the outer side of the wire supporting body; when the stator iron core is in a straight strip state, the gap bridge wires of the wound windings are located on the outer sides of the corresponding wire supporting bodies. When the stator iron core is in a circle forming state, the wire supporting bodies swing outwards towards the outer sides of the wire supporting bodies so as to abut against the bridging wires. According to the invention, the gap bridge wires on the round stator can be still kept in a tensioned state, the insulating framework effectively supports the gap bridge wires, and the gap bridge wires cannot move under the impact of a molding compound in the stator injection molding process, so that the gap bridge wires cannot be broken by punching, and the short circuit of the motor can be avoided.

Description

Technical Field

[0001] The present invention belongs to the technical field of motors, and in particular relates to a stator assembly and a motor having the same. Background Art

[0002] Household motors typically use a plastic-encapsulated stator structure. The stator typically features a multi-phase, multi-slot, multi-pole concentrated winding design. For example, a three-phase, 12-slot, 8-pole stator uses a concentrated winding design. The first-phase winding is wound around the 1st, 4th, 7th, and 10th teeth of the stator, respectively. A winding bridge wire spans the 2nd and 3rd teeth between the 1st and 4th teeth, and a winding bridge wire spans the 5th and 6th teeth between the 4th and 7th teeth. Similarly, each phase winding has multiple bridge wires. To improve motor production efficiency, the stator core of an inner rotor motor is typically made into a straight bar (or block) shape in the prior art. The core is wrapped with an insulating frame and wound with windings. The winding bridge wires pass through the frame of the stator yoke, and the straight bar core is then spliced ​​into a circular shape. Because the stator yoke of a straight core has multiple V-grooves, the V-grooves merge after the straight cores are assembled into a circle, reducing the circumference of the stator yoke. While the bridge wires are taut on the straight core, they become loose after the circle is formed. The more slots there are, the looser the bridge wires become. Without the support of an insulating core, these loose bridge wires can move with the molding compound during the stator injection molding process and easily break, causing a short circuit in the motor. Summary of the Invention

[0003] Therefore, the present invention provides a stator assembly that can solve the technical problem that after a straight iron core with an insulating frame and windings are spliced ​​into a circular stator, the winding bridge wires on the insulating frame become loose. Due to the lack of effective support from the insulating frame, the loose bridge wires are easily moved along with the plastic packaging material during the stator injection molding process and are broken, thereby causing a short circuit in the motor.

[0004] In order to solve the above problems, the present invention provides a stator assembly, including a stator core and an insulating frame, wherein the insulating frame is assembled on the stator core, the stator core includes a stator yoke and a plurality of stator teeth on the stator yoke, and the insulating frame includes a plurality of wire supports, each of the wire supports corresponds to the stator yoke, and each of the wire supports is spaced apart along the extension direction of the stator yoke, and the side of the wire support facing away from the stator teeth is the outer side of the wire support; the stator core has a straight state and a circular state, when the stator core is in the straight state, each bridge wire of the wound winding is located on the outer side of the corresponding wire support; when the stator core is in the circular state, each wire support is swung outward toward the outer side of the wire support to tighten each bridge wire.

[0005] In some embodiments, a plurality of clearance slots are constructed on the stator yoke. When the stator core is in a straight bar state, the clearance slots are spaced apart along the extension direction of the stator yoke. Two adjacent clearance slots are located on both sides of the corresponding stator teeth. In the process of the stator core changing from a straight bar state to a circular state, each clearance slot provides a deformation space. The insulating skeleton also includes a plurality of skeleton splits. Each skeleton split is spaced apart on the stator core. Each skeleton split includes a skeleton yoke and skeleton teeth on the skeleton yoke. Each skeleton yoke corresponds to the stator yoke. Each skeleton tooth corresponds to each stator tooth. Each support wire is respectively arranged on each skeleton yoke. When the stator core is in a circular state, each skeleton yoke is located between two adjacent clearance slots.

[0006] In some embodiments, between two adjacent frame parts, the support wires on the frame yoke of one frame part extend to above the frame yoke of the other frame part.

[0007] In some embodiments, each of the skeleton yokes is provided with a raised boss, and when the stator core is in a circular state, each of the raised bosses is located between two adjacent support wire bodies; the spacing between the part of the support wire body extending above the adjacent skeleton yoke and the adjacent skeleton yoke is a, and the height of the raised boss is b, b≥a.

[0008] In some embodiments, each of the skeleton yokes is provided with an inner block body and an outer block body. When the stator core is in a circular state, the inner block body and the outer block body on the same skeleton yoke are both located between two adjacent wire support bodies, and a wiring channel is formed between the inner block body and the outer block body on the same skeleton yoke.

[0009] In some embodiments, the raised boss on the same skeleton yoke is located between the inner stopper and the outer stopper on the same skeleton yoke.

[0010] In some embodiments, at least one of the inner stopper and the outer stopper abuts against the raised boss.

[0011] In some embodiments, the thickness of the inner barrier is c, the thickness of the support wire is d, and d≥c.

[0012] In some embodiments, a wire-clamping structure is formed on each of the wire-supporting bodies, and when the stator core is in a circular state, each of the bridge wires is respectively clamped to the wire-clamping structure.

[0013] The present invention also provides a motor, comprising the aforementioned stator assembly.

[0014] The present invention provides a stator assembly and a motor having the same, which have the following beneficial effects:

[0015] By configuring the insulating frame to include multiple wire supports, when the stator core is in a straight position, the bridge wires of each wound winding are located outside their corresponding wire supports. When the stator core is in a rounded position, each wire support swings outward to hold the bridge wires in place. This ensures that the bridge wires remain taut even after the stator core is rounded. The insulating frame effectively supports the bridge wires, preventing them from shifting under the impact of the molding compound during the stator injection molding process, preventing them from breaking and thus preventing motor short circuits. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] To more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for the embodiments or the description of the prior art. Obviously, the drawings described below are merely exemplary, and those skilled in the art can, without inventive effort, derive other implementation drawings based on the provided drawings.

[0017] Figure 1 This is a structural schematic diagram of the stator core and the insulating frame of the stator assembly in an embodiment of the present invention in a circular state;

[0018] Figure 2 This is a structural schematic diagram of the stator core and the insulating frame of the stator assembly in an embodiment of the present invention in a straight state;

[0019] Figure 3 for Figure 2 A is an enlarged schematic diagram;

[0020] Figure 4 A side view of the stator core and the insulating frame of the stator assembly of an embodiment of the present invention in a straight state;

[0021] Figure 5 for Figure 4 An enlarged schematic diagram of point B in FIG.

[0022] Figure 6 A top view of the stator core and the insulating frame of the stator assembly of an embodiment of the present invention in a straight state;

[0023] Figure 7 for Figure 6 The enlarged schematic diagram of point C in FIG.

[0024] Figure 8 A side view of a stator core and an insulating frame of a stator assembly according to an embodiment of the present invention;

[0025] Figure 9 Schematic diagram of the structure of the stator assembly according to an embodiment of the present invention.

[0026] The reference numerals indicate:

[0027] 1. Stator core; 2. Wire support; 3. Winding; 4. Bridge wire; 5. Frame split; 6. Raised boss; 7. Inner block; 8. Outer block; 9. Wire clamping structure; 10. Terminal pin; 11. Clearance slot; 12. Injection molding compound. DETAILED DESCRIPTION

[0028] The following will be combined with the accompanying 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 embodiments described are only part of the embodiments of the present invention, rather than all the embodiments. The following description of at least one exemplary embodiment is actually only illustrative and is in no way intended to limit the present invention and its application or use. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0029] In the description of the present invention, it should be understood that the directions or positional relationships indicated by directional words such as "front, back, up, down, left, right", "horizontal, vertical, perpendicular, horizontal" and "top, bottom" are usually based on the directions or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description. Unless otherwise specified, these directional words do not indicate or imply that the device or element referred to must have a specific direction or be constructed and operated in a specific direction. Therefore, they cannot be understood as limiting the scope of protection of the present invention; the directional words "inside and outside" refer to the inside and outside relative to the outline of each component itself.

[0030] For ease of description, spatially relative terms such as "above", "above", "on the upper surface of", "above", etc. may be used herein to describe the spatial positional relationship of a device or feature to other devices or features as shown in the figures. It should be understood that spatially relative terms are intended to include different orientations of the device in use or operation in addition to the orientation described in the figures. For example, if the device in the drawings is inverted, the device described as "above other devices or structures" or "above other devices or structures" will be positioned as "below other devices or structures" or "below other devices or structures". Thus, the exemplary term "above" can include both "above" and "below". The device can also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatially relative descriptions used here are interpreted accordingly.

[0031] In addition, it should be noted that the use of terms such as "first" and "second" to limit components is only for the convenience of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore cannot be understood as limiting the scope of protection of the present invention.

[0032] See also Figures 1 to 9 As shown, according to an embodiment of the present invention, a stator assembly is provided, comprising a stator core 1 and an insulating frame, wherein the insulating frame is assembled on the stator core 1, and the stator core 1 comprises a stator yoke and a plurality of stator teeth located on the stator yoke. The insulating frame comprises a plurality of wire supports 2, wherein each wire support 2 corresponds to the stator yoke, and each wire support 2 is spaced apart along the extension direction of the stator yoke, and the side of the wire support 2 facing away from the stator teeth is the outer side of the wire support 2; the stator core 1 has a straight state and a rounded state, and when the stator core 1 is in the straight state, the bridge wires 4 of each wound winding 3 are located on the outer side of the corresponding wire support 2; when the stator core 1 is in the rounded state, each wire support 2 swings outward toward the outer side of the wire support 2 to tighten each bridge wire 4.

[0033] In this technical solution, the insulating skeleton includes multiple wire supports 2. When the stator core 1 is in a straight state, the bridge wires 4 of each wound winding 3 are located outside the corresponding wire supports 2. When the stator core 1 is in a rounded state, each wire support 2 swings outward to the outside of the wire support 2 to tighten the bridge wires 4. This ensures that the bridge wires 4 on the rounded stator remain tensioned, and the insulating skeleton effectively supports the bridge wires 4. During the stator injection molding process, the bridge wires 4 will not move under the impact of the molding compound, thereby preventing the bridge wires 4 from being broken, thereby preventing short circuits in the motor.

[0034] See also Figures 1 to 3 As shown, a plurality of clearance slots 11 are constructed on the stator yoke. When the stator core 1 is in a straight bar state, the clearance slots 11 are spaced apart along the extension direction of the stator yoke. Two adjacent clearance slots 11 are located on both sides of the corresponding stator teeth. In the process of the stator core 1 changing from a straight bar state to a circular state, each clearance slot 11 provides a deformation space. The insulating skeleton also includes a plurality of skeleton splits 5. Each skeleton split 5 is spaced apart on the stator core 1. Each skeleton split 5 includes a skeleton yoke and skeleton teeth on the skeleton yoke. Each skeleton yoke corresponds to the stator yoke, and each skeleton tooth corresponds to each stator tooth. Each support wire 2 is respectively arranged on each skeleton yoke. When the stator core 1 is in a circular state, each skeleton yoke is located between two adjacent clearance slots 11.

[0035] In this embodiment, a plurality of clearance grooves 11 are constructed on the stator yoke, thereby providing deformation space for the stator yoke to bend into a circle. The skeleton segments 5 are spaced apart on the stator core 1 so that the skeleton segments 5 are independent of each other and not connected to each other. Then, after the stator core 1 changes from a straight bar state to a circular state, the skeleton segments 5 will automatically change into a circular state following the stator core 1. During this circular transformation process, the support wire bodies 2 will automatically swing outward to the outside of the support wire body 2, thereby tightening the bridge wires 4. The clearance grooves 11 can be V-shaped grooves, with the opening of the V-shaped grooves facing the side where the stator teeth are located. After the skeleton segments 5 change into a circular state following the stator core 1, the V-shaped grooves are closed. See. Figure 6 As shown, when the stator core 1 is in a straight state, the length of the bridge wire 4 is L; see Figure 1 As shown, when the stator core 1 is in a circular state, the length of the bridge wire 4 is L1+L2; see Figure 5 As shown, the length of the support wire body 2 is e. By adjusting the length of the support wire body 2, the tightness of the bridge wire 4 can be adjusted. The length of the support wire body 2 is controlled so that L=L1+L2 is the optimal situation.

[0036] See also Figure 2 and Figure 3 As shown, between two adjacent frame segments 5, the wire supports 2 on the yoke of one frame segment 5 extend above the yoke of the other frame segment 5. This allows each wire support 2 to cross over its corresponding clearance slot 11. Since the stator yoke bends at each clearance slot 11 during the process of the stator core 1 transforming from a straight bar into a circular state, after the wire support 2 crosses the clearance slot 11, the wire support 2 follows the stator yoke and swings outward with a relatively large amplitude, thereby achieving a better tightening effect of the wire support 2 on each bridge wire 4.

[0037] See also Figures 1 to 3 As shown, each skeleton yoke is provided with a raised boss 6. When the stator core 1 is in a circular state, each raised boss 6 is located between two adjacent support wire bodies 2. The distance between the part of the support wire body 2 extending above the adjacent skeleton yoke and the adjacent skeleton yoke is a, and the height of the raised boss 6 is b, b≥a.

[0038] In this technical solution, if the bridge wire 4 gets stuck between the portion of the wire support body 2 extending above the adjacent frame yoke and the adjacent frame yoke, the wire will be stuck, and the wire support function of the wire support body 2 will not be effectively exerted. By providing a lifting boss 6, and making the height of the lifting boss 6 greater than the distance between the portion of the wire support body 2 extending above the adjacent frame yoke and the adjacent frame yoke, the bridge wire 4 can be lifted by the lifting boss 6 to prevent the wire from getting stuck.

[0039] See also Figure 2 、 Figure 3 、 Figure 6 and Figure 7 As shown, each skeleton yoke is provided with an inner block body 7 and an outer block body 8. When the stator core 1 is in a circular state, the inner block body 7 and the outer block body 8 on the same skeleton yoke are both located between two adjacent wire support bodies 2, and a wiring channel is formed between the inner block body 7 and the outer block body 8 on the same skeleton yoke.

[0040] In this embodiment, an inner block 7 and an outer block 8 are provided to form a wiring channel therebetween, thereby facilitating the wiring of the bridge wire 4. It is understandable that the inner block 7 and the outer block 8 can form a barrier to the bridge wire 4 to prevent the bridge wire 4 from sliding out of the skeleton yoke. It should be noted that in the prior art, there is also a method of narrowing the wiring channel to prevent the bridge wire 4 from being loose, but if the width of the wire groove is too small, it will be detrimental to wiring. However, the present application tightens each bridge wire 4 by adding each support body 2, so there is no need to narrow the wiring channel, thereby achieving the tightening of the bridge wire 4 without affecting the wiring of the bridge wire 4.

[0041] See also Figure 2 and Figure 3 As shown, the raised boss 6 on the same frame yoke is located between the inner block 7 and the outer block 8 on the same frame yoke.

[0042] In this technical solution, by locating the raised boss 6 between the inner block 7 and the outer block 8, the blocking effect of the inner block 7 and the outer block 8 can be utilized to prevent the bridge line 4 from sliding easily after passing through the raised boss 6.

[0043] See also Figure 2 、 Figure 3 、 Figure 6 and Figure 7 As shown, at least one of the inner block body 7 and the outer block body 8 is in contact with the raised boss 6 , which has a better blocking effect on the bridge line 4 passing through the raised boss 6 , making it less likely for the bridge line 4 to slide off the raised boss 6 .

[0044] See also Figure 6 and Figure 7 As shown, the thickness of the inner block body 7 is c, the thickness of the support wire body 2 is d, and d≥c.

[0045] In this embodiment, when the thickness of the inner barrier 7 is less than or equal to the thickness of the wire support 2, indicating that the inner barrier 7 is relatively thin, the wiring channel formed between the inner barrier 7 and the outer barrier 8 will not be too narrow, thereby preventing the width of the wiring channel from being too narrow and affecting wiring. Specifically, the side of the skeleton yoke closest to the skeleton teeth is the inner side of the skeleton yoke, and the sides of the inner barrier 7 and the wire support 2 facing the skeleton teeth are both flush with the inner edge of the skeleton yoke.

[0046] See also Figure 1 As shown, a wire-locking structure 9 is formed on each wire-supporting body 2 . When the stator core 1 is in a rounded state, each bridge wire 4 is respectively locked in the wire-locking structure 9 .

[0047] In this technical solution, a wire-locking structure 9 is provided to hold the bridge wire 4, preventing it from moving up and down relative to the wire support body 2 along the stator's axial direction. The wire-locking structure 9 can be a slot formed on the outwardly swung end of the wire support body 2, or a protrusion formed on the outwardly swung end of the wire support body 2, as long as it can hold the bridge wire 4. It should be noted that the stator assembly also includes terminal pins 10, to which the wire ends of the windings 3 are welded.

[0048] The manufacturing method of the stator assembly is as follows:

[0049] 1. Production of stator core 1: According to the slot size and functional requirements of the stator core 1, a suitable mold design scheme is formulated. The steel plate base material can be laminated into the stator core 1 using a special high-impact mold. The base material is preferably silicon steel sheet ( Figure 2 );

[0050] 2. Production of stator core assembly: Place the stator core 1 in a dedicated injection mold cavity, and completely wrap the stator core 1 with injection plastic 12 axially to the teeth and yoke of the stator core 1, so that the stator core 1 and the winding 3 are effectively isolated. The injection plastic forms an insulating skeleton. The injection molding material is preferably an insulating material such as PBT or PA66 ( Figure 4 );

[0051] 3. Stator production: Use a high-precision winding machine to wind the stator winding coil according to the predetermined winding scheme, wind it on the stator teeth, and wind the winding wire ends and tails to the corresponding pins respectively. The end faces are welded firmly with terminal blocks to complete the stator production. The material of the stator winding coil is preferably enameled copper wire or enameled aluminum wire ( Figure 1 and Figure 8 );

[0052] 4. Stator assembly production: Use a dedicated injection mold to inject the material to form a base. The base is provided with a base boss. Press the bearing and stator into the base boss in a specific order to complete the stator assembly. The injection material is preferably BMC or a strong insulating material ( Figure 9 ).

[0053] The present invention also provides a motor, comprising the aforementioned stator assembly.

[0054] It is easy for those skilled in the art to understand that, under the premise of no conflict, the advantageous technical features of the above-mentioned methods can be freely combined and superimposed.

[0055] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the present invention. The above are merely preferred embodiments of the present invention. It should be noted that those skilled in the art may make various improvements and variations without departing from the technical principles of the present invention, and such improvements and variations shall also be considered within the scope of protection of the present invention.

Claims

1. A stator assembly, characterized in that: The invention comprises a stator core (1) and an insulating frame, wherein the insulating frame is assembled on the stator core (1), the stator core (1) comprises a stator yoke and a plurality of stator teeth located on the stator yoke, and the insulating frame comprises a plurality of wire supports (2), each of the wire supports (2) corresponds to the stator yoke, and each of the wire supports (2) is spaced apart along the extension direction of the stator yoke, and the side of the wire supports (2) facing away from the stator teeth is the outside of the wire supports (2); the stator core (1) has a straight state and a round state, and when the stator core (1) is in the straight state, the bridge wires (4) of each wound winding (3) are located outside the corresponding wire supports (2); when the stator core (1) is in the round state, each of the wire supports (2) swings outwards to the outside of the wire supports (2) to press each of the bridge wires (4) tightly.

2. The stator assembly according to claim 1, characterized in that: The stator yoke is provided with a plurality of clearance slots (11). When the stator core (1) is in a straight bar state, the clearance slots (11) are spaced apart along the extension direction of the stator yoke. Two adjacent clearance slots (11) are located on both sides of the corresponding stator teeth. When the stator core (1) is transformed from a straight bar state to a circular state, the clearance slots (11) provide deformation space. The insulating skeleton further comprises a plurality of skeleton segments (5). Each skeleton segment (5) is spaced apart on the stator core (1). Each skeleton segment (5) comprises a skeleton yoke and skeleton teeth on the skeleton yoke. Each skeleton yoke corresponds to the stator yoke. Each skeleton tooth corresponds to each stator tooth. Each support wire body (2) is respectively arranged on each skeleton yoke. When the stator core (1) is in a circular state, each skeleton yoke is located between two adjacent clearance slots (11).

3. The stator assembly according to claim 2, characterized in that: Between two adjacent skeleton parts (5), the support wire body (2) on the skeleton yoke of one of the skeleton parts (5) extends to the top of the skeleton yoke of the other skeleton part (5).

4. The stator assembly according to claim 3, characterized in that: Each of the skeleton yokes is provided with a raised boss (6), and when the stator core (1) is in a circular state, each of the raised bosses (6) is located between two adjacent support wire bodies (2); the spacing between the portion of the support wire body (2) extending above the adjacent skeleton yoke and the adjacent skeleton yoke is a, and the height of the raised boss (6) is b, where b≥a.

5. The stator assembly according to claim 4, characterized in that: An inner stopper (7) and an outer stopper (8) are provided on each of the skeleton yokes. When the stator core (1) is in a circular state, the inner stopper (7) and the outer stopper (8) on the same skeleton yoke are both located between two adjacent wire support bodies (2), forming a wiring channel between the inner stopper (7) and the outer stopper (8) on the same skeleton yoke.

6. The stator assembly according to claim 5, characterized in that: The raised boss (6) on the same skeleton yoke is located between the inner block body (7) and the outer block body (8) on the same skeleton yoke.

7. The stator assembly according to claim 6, characterized in that: At least one of the inner block body (7) and the outer block body (8) abuts against the raised boss (6).

8. The stator assembly according to claim 5, characterized in that: The thickness of the inner block body (7) is c, and the thickness of the support wire body (2) is d, where d≥c.

9. The stator assembly according to any one of claims 1 to 8, characterized in that: A wire clamping structure (9) is formed on each of the wire support bodies (2); when the stator core (1) is in a circular state, each of the bridge wires (4) is respectively clamped to each of the wire clamping structures (9).

10. A motor, characterized in that: Comprising the stator assembly according to any one of claims 1 to 9.

Images