Stator assembly of electronic oil pump motor

Abstract

The invention discloses a stator assembly of an electronic oil pump motor, which comprises a coil holder assembly and a stator iron core group, and is characterized in that the stator iron core group comprises a plurality of iron core units, and the plurality of iron core units are connected end to end and are arranged in a straight row; every two adjacent iron core units are integrally connected through a connecting bridge, and every two iron core units located at the head end and the tail end are fixedly connected through a connecting structure after being rolled. The iron core units are provided with connecting parts, the connecting parts are arc-shaped, the connecting bridges are arranged between two adjacent connecting parts, and the inner arcs of the connecting parts extend outwards to form winding teeth; protrusions extending towards the two sides are arranged at the tail ends of the winding teeth, and after the stator iron core set is rolled, every two adjacent protrusions are matched to form a notch. The motor has the beneficial effects that the stator iron core group adopts a straight-row design, the material utilization rate is high, the winding flexibility can be further improved, the width of a notch is greatly reduced, and the winding space is effectively improved; the winding machine has the advantages of convenience in winding, high slot fullness rate, high automation degree and the like.

Description

Technical Field

[0001] This application relates to the field of engineering machinery and new energy vehicle parts technology, and in particular to a stator assembly of an electronic oil pump motor. Background Technology

[0002] With the continuous development of technology, electronic oil pumps have begun to be widely used in automobiles, industry, and shipbuilding. The motor stator assembly, as a crucial component of the electronic oil pump motor, plays a decisive role in the motor's operating efficiency. However, existing stator assemblies have several problems. Traditional stator assembly designs suffer from insufficient slot fill factor (typically 40%–50%), resulting in low power density in the oil pump motor. Furthermore, in most oil pump motors, the stator and motor housing are assembled using adhesive or heat-shrink fitting, leaving the stator constantly immersed in hot oil, which poses a risk of failure.

[0003] In existing technologies, cables are typically wound directly onto the already coiled stator. This winding process is quite difficult, and the slot width needs to be designed to accommodate the cable passage, resulting in a relatively large slot fill factor. Furthermore, the cable arrangement is relatively loose, making the insulation layer prone to wear under long-term vibration. Therefore, there is an urgent need for a stator assembly that is simple to wind and has high working efficiency. Summary of the Invention

[0004] One objective of this application is to provide a stator assembly for an electronic oil pump motor that can solve at least one of the defects in the aforementioned background art.

[0005] To achieve at least one of the above objectives, the technical solution adopted in this application is as follows: a stator assembly for an electronic oil pump motor, comprising a wire frame assembly and a stator core assembly, wherein the stator core assembly comprises multiple core units connected end-to-end in a straight line; adjacent core units are integrally connected by a connecting bridge, and the two core units at the beginning and end are provided with mutually cooperating connecting structures; the stator core assembly is rolled into a circle and then fixedly connected by the connecting structures; the rolled and fixed stator core assembly is installed inside the wire frame assembly; a connecting portion is provided on the core unit, the connecting portion is arc-shaped, the connecting bridge is provided between two adjacent connecting portions, and winding teeth extend outward from the inner arc of the connecting portion; the ends of the winding teeth are provided with protrusions extending to both sides, and after the stator core assembly is rolled into a circle, two adjacent protrusions cooperate to form a slot.

[0006] By configuring the stator core assembly into a straight-line structure, the flexibility of winding can be further improved (horizontal or vertical winding is possible). In the straight-line state, the cable is wound onto the winding teeth and then rolled into a circle, which greatly reduces the width of the slots, effectively increasing the winding space and slot fill factor. The connection structure ensures that the rolled stator core assembly has high stability, preventing the core units from unraveling under their own elasticity.

[0007] Preferably, the connecting bridge is arc-shaped, and the included angle between the inclined surfaces corresponding to two adjacent connecting parts is 30°. This design allows the stator core assembly to be rolled into a more circular shape after being rolled, which is more conducive to subsequent installation. Setting the included angle between the inclined surfaces corresponding to the two connecting parts at 30° ensures that the stator core assembly has sufficient rolling space while minimizing the width of the slot.

[0008] Preferably, the connection structure includes a welding notch and a welding protrusion. After the stator core assembly is rolled into a circle, the welding protrusion extends into the welding notch. With this configuration, when the stator core assembly is rolled into a circle after winding, the welding protrusion extends into the welding notch, and then the two are welded together. This effectively avoids misalignment of the rolled stator core assembly, further improving the welding efficiency of the stator core assembly.

[0009] Preferably, the stator core assembly adopts a 12-slot structure and is used in conjunction with a 10-pole rotor assembly, wherein the 10-pole rotor assembly adopts a surface-mount magnetization design. This configuration effectively increases the number of magnetic field cycles through the 10-pole rotor assembly, reducing iron losses (eddy current and hysteresis losses) and improving efficiency at the same rotational speed. The 12-slot stator structure facilitates automated winding production, reducing manufacturing costs.

[0010] Preferably, the angle between the winding teeth and the protrusion is 122.5°, and the width of the slot is no greater than 0.4mm. This configuration effectively reduces cable stress concentration and increases slot fill factor.

[0011] Preferably, a motor housing is also installed on the outer side of the stator assembly, and a limiting structure is provided between the motor housing and the stator core assembly. This arrangement can effectively prevent the stator from rotating relative to the motor housing and can serve as an assembly reference to ensure the concentricity of the stator and the motor housing.

[0012] Preferably, the stator core assembly is concentrically arranged with the motor housing. The limiting structure includes a groove and a boss. The groove is located on the inner side of the motor housing, and the boss is located on the outer side of the stator core assembly. This arrangement allows the boss to be embedded into the groove during stator core assembly installation, preventing misalignment when the stator assembly is pressed into the motor housing, reducing magnetic field asymmetry caused by uneven air gap, improving motor efficiency, and reducing vibration and noise.

[0013] Preferably, the wire frame assembly includes an upper wire frame and a lower wire frame, with the upper wire frame and the lower wire frame forming a toothed groove, and the stator core assembly installed in the toothed groove. Both the upper and lower wire frames adopt a modular design, allowing them to be used with stator core assemblies of different diameters, heights, and power ratings. This configuration allows for flexible combination of the upper and lower wire frames, further improving the applicability of the wire frame assembly and contributing to cost savings and increased production efficiency.

[0014] Preferably, the thickness of the mating part of the tooth groove is 0.25 mm. This setting maximizes the effective space for winding while ensuring strength.

[0015] Preferably, the upper and lower wire frames are made of PPS + glass fiber composite material. This configuration gives the upper and lower wire frames high mechanical strength, as well as excellent oil resistance, high temperature resistance, and insulation properties.

[0016] Compared with the prior art, the beneficial effects of this application are as follows: (1) The stator core assembly of the present invention adopts a straight-line design, which has a high material utilization rate and can further improve the flexibility of winding. The cable is wound into the straight-line stator core assembly and then rolled into a circle, which greatly reduces the width of the slot and effectively increases the winding space and slot fill factor. The welded concave-convex interface design enhances the integrity of the core through mechanical interlocking, avoiding the loosening or misalignment of the core laminations due to high-frequency vibration or impact, thereby reducing noise and wear. In addition, the concave-convex interface facilitates precise alignment of the laminations, which is suitable for automated stacking processes (such as high-speed stamping + riveting), reduces manual intervention, and improves production efficiency and consistency.

[0017] (2) The 12-slot, 10-pole configuration is a fractional-slot design, which significantly reduces torque, makes the motor run more smoothly, and reduces vibration and noise, making it particularly suitable for noise-sensitive automotive environments. The 10-pole rotor assembly design increases the number of magnetic field cycles, which reduces iron losses (eddy current and hysteresis losses) and improves efficiency at the same speed. The multi-pole structure shortens the magnetic flux path, reduces magnetic resistance, and enhances torque output, making it more suitable for scenarios where oil pumps require rapid response. In addition, the 12-slot stator structure facilitates automated winding production and reduces manufacturing costs; the 10-pole rotor adopts a surface-mount magnetization design, which balances performance and process feasibility.

[0018] (3) The limiting structure between the motor housing and the stator core assembly can effectively prevent the stator from rotating relative to the motor housing. The fit between the boss and the groove can serve as an assembly reference to ensure the concentricity of the stator and the motor housing, prevent the stator assembly from being pressed into the motor housing at the wrong position, reduce the magnetic field asymmetry caused by uneven air gap, improve motor efficiency and reduce vibration noise.

[0019] (4) The upper and lower wire frames can be flexibly combined, so that the wire frame assembly in this invention can be matched with a series of motor stators of different heights (different power) with the same diameter, which can save costs and improve production efficiency. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of the stator assembly in this application.

[0021] Figure 2 This is a schematic diagram of the core unit in this application.

[0022] Figure 3 This is a schematic diagram of the cross-sectional structure of the stator assembly in this application.

[0023] Figure 4 This is a schematic diagram of the straight-line structure of the stator core assembly in this application.

[0024] Figure 5 for Figure 4 A magnified structural diagram of part A in the middle.

[0025] Figure 6 This is a schematic diagram of the rolled-up state of the stator core assembly in this application.

[0026] Figure 7 for Figure 6 A magnified structural diagram of local area B in the middle.

[0027] Figure 8 This is a schematic diagram of the structure of the motor housing in this application.

[0028] Figure 9 This is a schematic diagram of the stator core assembly installation structure in this application. Figure 1 .

[0029] Figure 10 This is a schematic diagram of the stator core assembly installation structure in this application. Figure 2 .

[0030] Figure 11 This is a schematic diagram of the stator core assembly installation structure in this application. Figure 3 .

[0031] In the diagram: 1. Wire frame assembly; 11. Upper wire frame; 12. Lower wire frame; 100. Connecting bridge; 2. Stator core assembly; 21. Core unit; 200. Slot; 211. Connecting part; 212. Winding tooth; 213. Protrusion; 3. Motor housing; 300. Welding protrusion; 301. Welding notch; 400. Boss; 401. Groove; 500. Tooth groove. Detailed Implementation

[0032] The present application will be further described below with reference to specific embodiments. It should be noted that, without conflict, the various embodiments or technical features described below can be arbitrarily combined to form new embodiments.

[0033] In the description of this application, it should be noted that the terms "center", "lateral", "longitudinal", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc., which indicate the orientation and positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and should not be construed as limiting the specific protection scope of this application.

[0034] It should be noted that the terms "first," "second," etc., in the specification and claims of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence.

[0035] The terms “comprising” and “having”, and any variations thereof, in the specification and claims of this application are intended to cover non-exclusive inclusion, for example, a process, method, system, product, or device that includes a series of steps or units is not necessarily limited to those steps or units that are explicitly listed, but may include other steps or units that are not explicitly listed or that are inherent to such process, method, product, or device.

[0036] One aspect of this application provides a stator assembly for an electronic oil pump motor, such as... Figures 1-5 As shown, one preferred embodiment includes a wire frame assembly 1 and a stator core assembly 2. The stator core assembly 2 consists of multiple core units 21, which are connected end-to-end and arranged in a straight line to improve winding flexibility. Operators can directly wind cables onto the straight-line stator core assembly 2. Adjacent core units 21 are integrally connected by a connecting bridge 100. The two core units 21 at both ends have mutually cooperating connection structures. When the stator core assembly 2 is wound into a circle, it can be fixed by the connection structures to prevent it from unraveling under its own elasticity.

[0037] Specifically, such as Figure 1As shown, the stator core assembly 2, after being rolled and fixed, is installed in the wire frame assembly 1. A connecting part 211 is provided on the core unit 21, and the connecting part 211 is arc-shaped. A connecting bridge 100 is provided between two adjacent connecting parts 211. A winding tooth 212 extends outward from the inner arc of the connecting part 211. The end of the winding tooth 212 is provided with a protrusion 213 extending to both sides. When the stator core assembly 2 is rolled, the two adjacent protrusions 213 cooperate to form a slot 200.

[0038] It should be understood that traditional stator assemblies employ a full-circle design, which suffers from drawbacks such as low material utilization and high winding difficulty. Furthermore, the width of the slot 200 is relatively large due to the need to accommodate the wire passage, thus limiting the slot fill factor. However, stator slotting leads to uneven air gap magnetic permeability, generating harmonics; the wider the slot 200, the greater the losses and vibration noise caused by harmonics. Therefore, energy loss can be reduced by decreasing the width of the slot 200.

[0039] The stator core assembly 2 in this application adopts a straight-line design, which has a high material utilization rate; the straight-line winding is flexible (it can be wound horizontally or vertically), and the straight-line winding is then rolled into a circle, which greatly reduces the width of the slot 200 and effectively increases the winding space and increases the slot fill factor.

[0040] In an embodiment, such as Figure 4 and Figure 5 As shown, the connecting bridge 100 is arc-shaped, and the connecting part 211 has inclined surfaces on both sides. The included angle between the inclined surfaces corresponding to two adjacent connecting parts 211 is θ, where θ = 30°. After the straight stator core assembly 2 is rolled into a circle, the arc of the connecting bridge 100 makes the stator core assembly 2 more circular overall, which is beneficial for subsequent installation. In addition, the inclined surfaces on both sides make the rolling of the straight stator core assembly 2 smoother, and the inclined surfaces on adjacent connecting parts 211 can fit together after the stator core assembly 2 is rolled into a circle, so that the stator assembly in this application has a semi-closed slot design. Of course, in practical applications, if the number of core units 21 needs to be adjusted, the included angle θ between the inclined surfaces corresponding to two adjacent connecting parts 211 also needs to be changed according to the situation to ensure that the stator core assembly 2 can be rolled into a circle normally.

[0041] Understandably, after the straight-line stator core assembly 2 is rolled into a circle, its shape is fixed by welding. Traditional welding methods typically involve aligning the contact surfaces on both sides of the stator core assembly 2 before welding. While this welding method provides some fixation, it only welds the gaps between the surfaces and cannot withstand high tensile forces. Furthermore, the internal strength of the oil pump is considerable during operation, and long-term operation may cause the weld points to break.

[0042] To address the aforementioned problems, in some embodiments of this application, such as... Figure 6 and Figure 7 As shown, the connection structure includes a welding notch 301 and a welding protrusion 300. After the stator core assembly 2 is rolled into a circle, the welding protrusion 300 can be inserted into the welding notch 301, and then the two can be welded together to effectively prevent misalignment of the rolled stator core assembly 2. Compared with traditional welding methods, the welding protrusion 300 and welding notch 301 in this application can act as a locking mechanism, thereby distributing the pressure on the welding point and improving the stability of the rolled stator core assembly 2. In addition, the welding protrusion 300 and welding notch 301 can also serve a positioning function. Simply inserting the welding protrusion 300 into the welding notch 301 can align the core units 21 on both sides, effectively preventing misalignment of the rolled stator core assembly 2 and further improving the welding efficiency of the stator core assembly 2.

[0043] In addition, the design of the welding notch 301 and welding convex opening 300 enhances the integrity of the iron core through mechanical interlocking, preventing the iron core laminations from loosening or misaligning due to high-frequency vibration or impact, thereby reducing noise and wear. At the same time, the tightly interlocked laminations can reduce the air gap in the magnetic circuit, improve magnetic flux continuity, and enhance the electromagnetic efficiency of the stator. Furthermore, the concave and convex interfaces facilitate precise alignment of the laminations, making them suitable for automated stacking processes (such as high-speed stamping + riveting), reducing manual intervention, and improving production efficiency and consistency.

[0044] In this embodiment, as Figure 1 As shown, stator core assembly 2 adopts a 12-slot structure and is used in conjunction with a 10-pole rotor. This 12-slot and 10-pole combination is a fractional-slot design, which significantly reduces torque (the periodic torque fluctuation caused by changes in magnetic reluctance when the rotor is without current). This makes the motor run more smoothly, reducing vibration and noise, making it particularly suitable for noise-sensitive automotive environments. Furthermore, the 10-pole rotor design increases the number of magnetic field cycles, reducing iron losses (eddy current and hysteresis losses) at the same speed and improving efficiency. The multi-pole structure shortens the magnetic flux path, reduces magnetic reluctance, and enhances torque output, making it more suitable for scenarios where oil pumps require rapid response. The 12-slot stator structure facilitates automated winding production, reducing manufacturing costs.

[0045] Furthermore, the 10-pole rotor adopts a surface-mount magnetization design, which has advantages such as simple structure, low manufacturing cost, and small moment of inertia. In addition, surface-mount magnetization can also reduce air gap magnetic flux density harmonics by reasonably optimizing dimensions, slotting the rotor surface, and optimizing permanent magnet poles, making the waveform more sinusoidal, which is beneficial to improving motor performance.

[0046] In this embodiment, as Figure 6 and Figure 7As shown, the angle between the winding teeth 212 and the protrusion 213 is α, where α = 122.5°. When the cable needs to be wound, if the internal stress of the cable is too high, the stress can be released through the transition area between the winding teeth 212 and the protrusion 213, thereby reducing the concentration of stress in the cable and further improving the safety of the cable. In addition, in order to reduce the loss and vibration noise generated by harmonics, the width W of the slot 200 should not exceed 0.4 mm.

[0047] In this embodiment, as Figure 8 As shown, a motor housing 3 is also installed on the outside of the stator assembly. To prevent the stator assembly from rotating inside the motor housing 3, a limiting structure is provided between the motor housing 3 and the stator core group 2. When the stator core group 2 tends to rotate, the limiting structure can block the stator core group 2, effectively preventing the stator core group 2 from rotating relative to the motor housing 3. In addition, the limiting structure can also serve as an assembly reference to ensure the concentricity of the stator assembly and the motor housing 3.

[0048] Specifically, the stator core assembly 2 and the motor housing 3 are concentrically arranged. The limiting structure includes a groove 401 and a boss 400. The groove 401 is located on the inner side of the motor housing 3, and the boss 400 is located on the outer side of the stator core assembly 2. When installing the stator core assembly 2, the boss 400 can be aligned with the groove 401 first. Then, while ensuring that the boss 400 is embedded in the groove 401, the stator core assembly 2 is placed into the motor housing 3. This not only avoids misalignment of the stator core assembly 2 when it is pressed into the motor housing 3, but also reduces magnetic field asymmetry caused by uneven air gap, thereby improving motor efficiency and reducing vibration noise.

[0049] In this embodiment, as Figure 9 , Figure 10 and Figure 11 As shown, the wire frame assembly 1 includes two mating upper wire frame 11 and lower wire frame 12. When mated, the upper wire frame 11 and lower wire frame 12 form a toothed groove 500 between them. The stator core assembly 2 is installed within the toothed groove 500, which fixes and limits its position. The mating distance between the upper wire frame 11 and lower wire frame 12 is adjustable, meaning that the combination of the upper wire frame 11 and lower wire frame 12 is flexible, allowing it to be used with a series of motor stators of the same diameter but different heights (different power), thus saving costs and improving production efficiency.

[0050] Specifically, the thickness of the mating part of the toothed groove 500 is 0.25mm. This reasonable thickness can maximize the effective space for winding while ensuring strength. The upper wire frame 11 and the lower wire frame 12 are made of PPS + glass fiber composite material, which can ensure that the upper wire frame 11 and the lower wire frame 12 have high mechanical strength as well as excellent oil resistance, high temperature resistance and insulation performance.

[0051] The basic principles, main features, and advantages of this application have been described above. Those skilled in the art should understand that this application is not limited to the above embodiments. The embodiments and descriptions in the specification are merely the principles of this application. Various changes and modifications can be made to this application without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claims. The scope of protection claimed by this application is defined by the appended claims and their equivalents.

Claims

1. A stator assembly for an electronic oil pump motor, comprising a wire frame assembly (1) and a stator core assembly (2), characterized in that, The stator core assembly (2) includes multiple core units (21), which are connected end to end in a straight line. Adjacent core units (21) are connected as a whole by a connecting bridge (100). The two core units (21) at the beginning and end are provided with mutually cooperating connection structures. The stator core assembly (2) is rolled into a circle and then fixedly connected by the connection structure. The rolled and fixed stator core assembly (2) is installed in the wire frame assembly (1). The core unit (21) is provided with a connecting part (211), the connecting part (211) is arc-shaped, the connecting bridge (100) is provided between two adjacent connecting parts (211), the inner arc of the connecting part (211) extends outward with a winding tooth (212); the end of the winding tooth (212) is provided with a protrusion (213) extending to both sides, after the stator core assembly (2) is rolled into a circle, the two adjacent protrusions (213) cooperate to form a slot (200).

2. The stator assembly of the electronic oil pump motor as described in claim 1, characterized in that, The connecting bridge (100) is arc-shaped, and the included angle between the inclined planes corresponding to two adjacent connecting parts (211) is 30°.

3. The stator assembly of the electronic oil pump motor as described in claim 1, characterized in that, The connection structure includes a welding notch (301) and a welding protrusion (300). When the stator core assembly (2) is rolled into a circle, the welding protrusion (300) extends into the welding notch (301).

4. The stator assembly of the electronic oil pump motor as described in claim 1, characterized in that, The stator core assembly (2) adopts a 12-slot structure and is used in conjunction with a 10-pole rotor assembly, wherein the 10-pole rotor assembly adopts a surface-mount magnetization design.

5. The stator assembly of the electronic oil pump motor as described in claim 1, characterized in that, The angle between the winding tooth (212) and the protrusion (213) is 122.5°, and the width of the slot (200) is no greater than 0.4 mm.

6. The stator assembly of the electronic oil pump motor as described in claim 1, characterized in that, A motor housing (3) is also installed on the outside of the stator assembly, and a limit structure is provided between the motor housing (3) and the stator core assembly (2).

7. The stator assembly of the electronic oil pump motor as described in claim 6, characterized in that, The stator core assembly (2) is concentrically arranged with the motor housing (3). The limiting structure includes a groove (401) and a boss (400). The groove (401) is located on the inner side of the motor housing (3), and the boss (400) is located on the outer side of the stator core assembly (2).

8. The stator assembly of the electronic oil pump motor as described in claim 1, characterized in that, The wire frame assembly (1) includes an upper wire frame (11) and a lower wire frame (12). The upper wire frame (11) and the lower wire frame (12) form a toothed groove (500). The stator core assembly (2) is installed in the toothed groove (500). The upper wire frame (11) and the lower wire frame (12) are both modularly designed. After the two are combined, they can be used with stator core assemblies (2) of different diameters, heights and power.

9. The stator assembly of the electronic oil pump motor as described in claim 8, characterized in that, The thickness of the mating part of the tooth groove (500) is 0.25 mm.

10. The stator assembly of the electronic oil pump motor as described in claim 8, characterized in that, The upper wire frame (11) and the lower wire frame (12) are made of PPS+glass fiber composite material.

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