Flat wire stator assembly formed by injection molding at groove bottom and end part of stator core and manufacturing method of flat wire stator assembly

Abstract

The invention discloses a flat wire stator assembly formed by injection molding at the groove bottom and the end part of a stator core and a manufacturing method thereof, and belongs to the technical field of stator core manufacturing, the flat wire stator assembly comprises a stator core (1), a yoke part (2), a tooth part (3), an insulator I (5), an insulator II (6), a flat wire wave winding wire winding (7), an insulator III (8) and an insulator IV (9), the manufacturing method comprises a stator iron core manufacturing process, a first injection molding process, a flat wire winding process, a process of embedding the flat wire into a mold II, a process of pressing the flat wire into a stator iron core groove body and the like, traditional insulation paper can be replaced, the insulation failure risk caused by abrasion of the insulation paper is avoided, and the service life of the insulation paper is prolonged. The insulation reliability of the stator assembly is greatly improved, the winding short circuit risk is avoided, the service life of the motor is prolonged, and the product quality is improved.

Description

Technical Field

[0001] This invention belongs to the field of stator core manufacturing technology, specifically relating to a flat wire stator assembly injection molded at the bottom and end of the stator core slot, and a method for manufacturing the flat wire stator assembly. Background Technology

[0002] Patent application No. 201810574019.5, filed on June 6, 2018, discloses a flat wire continuous wave-wound staggered winding and a stator containing the winding. The flat wire continuous wave-wound staggered winding consists of an inlet conductor section, an outlet conductor section, and an S-shaped waveform line continuously wound into an S-shape between the inlet and outlet conductor sections. The S-shaped waveform line includes an effective side portion for placement within the stator slot, straight sections located outside the slot on both sides, and ends connecting adjacent straight sections. In the S-shaped waveform line, staggered winding sections are provided, and the conductors in each phase of the staggered winding section are interconnected. The stator, comprising a stator core, includes a yoke and teeth. Slots are arranged circumferentially within the stator core, and slot insulation paper is placed within each slot. Conductor windings are arranged within the slot insulation paper, and these conductor windings are configured as flat wire continuous wave windings with staggered arrangement. This invention enables single-phase and three-phase control for motors or generators with varying numbers of slots per pole and phase. This simplifies motor circuitry, reduces manufacturing costs, lowers second harmonics, reduces motor noise, and improves product quality.

[0003] However, like other existing products, the stator core has insulating paper installed in the slot and wire windings installed inside the insulating paper. During motor operation, the insulating paper is subjected to repeated friction and stress due to the vibration and temperature changes of the core, which can easily cause wear, aging or even cracking. Especially at the corners and edges of the slot, the wear is more severe, which leads to loss of insulation function and thus adversely affects the performance of the motor. On the other hand, since the wires at both ends of the stator core (1) are exposed, during motor operation, the insulation layer may be damaged due to friction between the end wires, between the wires and the core or other components, which can cause short circuits, shorten the service life of the motor and affect the normal operation of the motor. Summary of the Invention

[0004] The purpose of this invention is to overcome the technical problems in the prior art where insulating paper is placed in the stator core slots and the wires at both ends of the stator core are exposed, which affect the performance and normal operation of the motor. This invention provides a flat wire stator assembly with injection molding at the bottom and ends of the stator core slots to replace the insulating paper, thereby preventing interference with the normal operation of the motor and improving its performance. Furthermore, this invention also provides a method for manufacturing this flat wire stator assembly to improve production efficiency and product quality.

[0005] To solve the above-mentioned technical problems, the present invention provides a flat wire stator assembly injection molded at the bottom and end of the stator core slots. The stator assembly includes a stator core, which includes a yoke and a toothed portion. A toothed slot is provided circumferentially on the inner side of the stator core. An injection-molded insulator I is provided on the inner wall of the slot bottom. An injection-molded insulator II is provided on the inner ring of the two end faces of the toothed portion and the two end faces of the yoke. A flat wire corrugated conductor winding is provided within the slot of the insulator I. An injection-molded insulator III is provided at both ends of the flat wire corrugated conductor winding. An injection-molded insulator IV is provided on the inner ring surface of the toothed slot. Insulator III and Insulator IV are integrally formed. A terminal is provided on the outer end face of Insulator III. The flat wire corrugated conductor winding is configured as a flat wire continuous corrugated staggered winding. The staggered winding consists of an input conductor section, an output conductor section, and an S-shaped waveform line continuously wound into an S-shape between the input and output conductor sections. The S-shaped waveform line includes an effective side portion for placement within the stator slot, straight sections located outside the slot on both sides, and ends connecting adjacent straight sections. A staggered winding section is provided within the S-shaped waveform line. The staggered winding section is positioned with staggered arrangement of the conductors within each phase conductor. The staggered winding section is located in the middle of the entire S-shaped waveform line. Alternatively, the S-shaped waveform line may have a staggered winding section in each wave winding of the same direction, spaced one wave winding apart. Based on the number of slots q distributed per pole per phase, in the wave winding composed of the U, V, and W phase windings, the pitch y1 of the U1 line in the U phase line is set as follows: y1 = q × m + (q - 1) In the formula: y represents the pitch. q represents the number of slots distributed per pole per phase. m represents the number of phases. The pitch y of line Ua a Set to: Y a = q × m -1, a is set to 2 to 7. In the V-phase line, the pitch y1ˊ of the V1 line is set as: y1ˊ = q × m + (q-1) The pitch y of line Va a ˊ Set to: Y a ˊ = q × m -1, a is set to 2 to 7. In the W-phase line, the pitch y1″ of the W1 line is set as: y1″ = q × m + (q-1) The pitch y of the Wa line a ˊ Set to: Y a " = q × m -1, 'a' can be set to 2 to 7.

[0006] The present invention also provides a method for manufacturing a flat wire stator assembly by injection molding at the bottom and end of the stator core slot, the method comprising the following steps: Step 1: Stator core manufacturing process. The silicon steel strip is cut to a width equal to the axial length of the stator core. The cut silicon steel strip is then leveled by a leveling machine and conveyed to a progressive die stamping mold. The silicon steel strip is stamped in the progressive die stamping mold to punch continuous fastening points and grooves. The silicon steel strip is then fed into a winding mechanism, where the starting end is fixed to the winding mold. By rotating the winding mold, the silicon steel strip is wound into a spiral loose semi-finished product with a predetermined number of turns. After shearing, it is separated into individual spiral units. The spiral units are then placed in the stator core forming mold, aligning the fastening points and grooves of adjacent silicon steel strips. By pressing, the silicon steel strip is pressed into a stator core. Step Two: The first injection molding process is performed at the bottom of the stator core slots. The stator core is cleaned to remove surface oil, impurities, etc., ensuring good bonding between the insulation material and the stator core body during injection molding. The stator core is then placed into the first stator core injection mold. A second mold core is inserted into the center of the stator core, with the teeth of the mold core corresponding to the grooves of the stator core. A gap of 0.15-0.22mm is maintained between the teeth of the mold core and the grooves of the stator core. A gap of 1-1.5mm is maintained between the upper inner ring of the mold core and the upper inner ring of the stator core. A gap of 1-1.5mm is set between the lower inner ring of mold core one and the lower inner ring of stator core. The mold is closed, and the molten insulating material is injected into the cavity of mold core one. The insulating material fills the cavity under pressure, forming the first injection molded insulator on the inner wall of the bottom of the stator core tooth groove. The second injection molded insulator is formed on the inner ring of the two end faces of the stator core teeth and the two end faces of the yoke. The pressure in mold core one is maintained. After the materials of the first and second insulators cool and solidify, mold core one is opened and the flat wire stator groove bottom injection molded stator core after the first molding is taken out. Step 3: Flat wire winding process. Prepare a winding mold that matches the structure and size of the stator core slot. The winding mold has winding trajectory slots corresponding to the effective side portion, straight portion, and end portion to ensure accurate shaping during flat wire winding. Fix one end of the flat wire to the inlet end of the winding mold as the starting end of the inlet conductor portion. According to the preset winding trajectory, continuously wind the conductor into an S-shape on the winding mold to form the effective side portion, straight portion, and end portion. During the winding process, strictly control the conductor tension to ensure the tightness and consistency of the winding. According to the setting method of the staggered winding part, perform staggered winding at the corresponding position. When the staggered winding part is set in the middle position of the entire S-shaped waveform, adjust the position of the conductor at the middle position so that the conductors in each phase conductor are staggered with each other. When the staggered winding part is set in the same direction wave winding every other wave winding, perform staggered winding when winding to the corresponding wave winding position. When winding U, V, W... When the three-phase winding is composed of wave windings, the winding is carried out according to the following pitch requirements based on the number of slots q distributed per pole per phase: In the U phase line, the pitch y1 of the U1 line is set as: y1=q×m +(q-1), where y represents the pitch, q represents the number of slots distributed per pole per phase, and m represents the number of phases; the pitch ya of the Ua line is set as: Ya= q×m -1, where a is 2 to 7; In the V phase line, the pitch y1ˊ of the V1 line is set as: y1ˊ=q×m +(q-1); the pitch yaˊ of the Va line is set as: Yaˊ= q×m -1, where a is 2 to 7; In the W phase line, the pitch y1″ of the W1 line is set as: y1″=q×m +(q-1); the pitch ya″ of the Wa line is set as: Ya″= q×m -1, where a is 2 to 7; After winding to the preset length, fix the other end of the wire to the wire outlet fixing position of the winding mold to form the wire outlet section, thus completing the winding of the entire winding. After the winding is completed and shaped, it is removed from the winding mold and prepared to be embedded into the slot of the stator core. Step 4: The process of embedding the flat wire into mold 2. Mold 2 is a positioning mold adapted to the structure of the flat wire winding. Its surface is provided with grooves corresponding to the effective side part and straight part of the S-shaped waveform. The size and shape of the grooves match the various parts of the flat wire winding to ensure that the flat wire winding can be accurately embedded and positioned. The flat wire winding is removed from the winding mold and embedded into the groove of mold 2. Step 5: Pressing the flat wire into the stator core slots: First, transfer the stator core, which has undergone the first injection molding, to mold three, allowing the stator core to rotate around its own axis. Control the rotation of the stator core to a preset angle, and use the positioning device of mold three to position and fix the stator core, ensuring that each slot on the stator core is in a position that facilitates receiving the flat wire winding. Then, place mold two, which contains the flat wire winding, in the middle position of the stator core. Adjust the position of mold two so that the direction and position of the groove on mold two are aligned with the slots on the stator core, ensuring that the flat wire winding in mold two can be accurately aligned with the slots of the stator core when pressed in. A pressing device is installed on mold two, which includes a drive mechanism and a pressing block. The driving device generates a pressing force perpendicular to the groove on mold two, causing the pressing block to move perpendicular to the groove on mold two. After mold two is aligned with the slot of the stator core, the pressing device on mold two is activated. The pressing device applies a uniform pressing force to the flat wire winding in the groove of mold two. Under the action of the pressing block, the effective side of the flat wire winding is separated from the groove of mold two and gradually pressed into the corresponding slot of the stator core. During the pressing process, the pressure and pressing speed of the pressing device need to be controlled. The pressure should be sufficient to allow the flat wire winding to enter the slot smoothly, while avoiding deformation or damage to the flat wire winding due to excessive pressure. The pressing speed should be kept stable to ensure that the effective side is evenly and accurately embedded into the slot. Step Six: Shaping Process. After pressing the effective edge portion of the flat wire into the stator core slot, transfer the stator core to mold four and shape the flat wires at both ends of the stator core. Step 7: Secondary injection molding process. After the two ends of the stator core are shaped, the stator core is transferred to mold five. Then, mold core two is placed in the middle of the stator core, the mold is closed, and the molten insulating material is injected into the cavity of mold five. The insulating material fills the cavity under pressure. Insulator three is injection molded around the conductors at both ends of the stator core and in the gaps between the slots. The pressure inside mold five is maintained. After the material of insulator three cools and solidifies, mold five is opened, and the flat wire stator injection molded stator core after the second injection molding is taken out. Step 8: Heating and shaping process. The stator core after secondary injection molding is transferred to mold six and heated. The temperature in mold six is ​​set to 140℃-170℃ and the heating time is set to 2 to 5 minutes for curing. Step Nine: Cooling process. Place the heated and shaped stator core into mold seven, then cool it down. Finally, remove the stator core from mold seven.

[0007] As a further improvement of the present invention, in the above-mentioned method for manufacturing the flat wire stator assembly, in step one, the mold is kept rotating at a constant speed during the winding process, and the silicon steel strip is continuously wound along the spiral trajectory with a constant tension to form an annular stator core blank. The tension of the silicon steel strip is controlled at 50-200N to ensure that the interlayer gap of the stator core is ≤0.03mm.

[0008] As a further improvement of the present invention, in the manufacturing method of the above-mentioned flat wire stator assembly, in step two, the insulating material is set as phenolic plastic or epoxy plastic, and the temperature in mold one is set as 70℃-90℃.

[0009] As a further improvement of the present invention, in the above-mentioned method for manufacturing the flat wire stator assembly, when continuously winding the S-shaped waveform wire in step three, the inner wall of the winding track groove on the winding mold is provided with a wear-resistant coating, and the width of the winding track groove is 0.05-0.1 mm larger than the thickness of the flat wire. During the winding process, the fit between the flat wire and the inner wall of the winding track groove is not less than 95%, so as to reduce wear during winding and ensure forming accuracy.

[0010] As a further improvement of the present invention, in the manufacturing method of the above-mentioned flat wire stator assembly, in step three, when continuously winding the S-shaped waveform wire, a rotatable guide wheel is provided at the end turning position of the winding mold. The wheel surface of the guide wheel and the contact surface of the flat wire have an arc-shaped adaptation structure, and the rotation speed of the guide wheel is synchronized with the winding speed, so as to reduce the frictional resistance of the wire when the end turns and improve the stability of the winding process.

[0011] As a further improvement of the present invention, in the above-mentioned method for manufacturing the flat wire stator assembly, when the flat wire is embedded into the groove of the mold second in step four, a guide positioning component is used to assist in alignment. The guide positioning component includes a tapered guide portion disposed at the inlet end of the groove of the mold second and limiting bosses on both sides. The taper of the tapered guide portion is 15°-30°, and the gap between the limiting bosses and the side of the flat wire winding does not exceed 0.03mm, ensuring that the flat wire winding is accurately embedded into the groove along a preset trajectory.

[0012] As a further improvement of the present invention, in the above-mentioned method for manufacturing the flat wire stator assembly, during the process of pressing the flat wire into the stator core slot in step five, the pressure of the pressing device is monitored in real time by a pressure sensor. The initial pressure is set to 30-50N. When the effective side portion of the flat wire winding enters the stator core slot to a depth of 1 / 3 of its total length, the pressure is automatically adjusted to 50-80N, and the pressing speed is maintained at 2-5mm / s until the effective side portion is completely pressed into the slot.

[0013] As a further improvement of the present invention, in the above-described method for manufacturing the flat wire stator assembly, during the secondary injection molding process in step seven, multiple vent holes are provided on the inner wall of the cavity of mold four. The diameter of the vent holes is 0.2-0.3 mm, and they are evenly distributed along the circumference of the cavity, with a spacing of 15-20 mm between adjacent vent holes. This facilitates timely gas discharge during the filling of the cavity with insulating material, preventing the formation of air holes in the injection molded product.

[0014] As a further improvement of the present invention, in the above-mentioned manufacturing method of the flat wire stator assembly, during the cooling and solidification process in step nine, a circulating water cooling system is used to rapidly cool mold six, with the cooling water temperature controlled at 15-20°C and the cooling time being 8-12 minutes. This improves mold turnover efficiency and avoids product deformation caused by thermal stress. After cooling, an ejection mechanism is used to smoothly push the stator core out of mold six.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. By setting insulator one at the bottom of the stator core slot, insulator two at the end faces of the teeth and yoke, insulator three at both ends of the winding, and insulator four on the inner ring of the slot, and insulator three and insulator four are integrally formed, a complete insulation system covering the bottom, ends, and inner ring of the slot is formed, replacing traditional insulating paper, avoiding the risk of insulation failure caused by the wear of insulating paper, and greatly improving the insulation reliability of the stator assembly; 2. When the flat wire is embedded in mold two, it is positioned by the aid of the conical guide and the limiting boss, and the pressure sensor is used for real-time monitoring when pressing into the slot, realizing 3. Precise embedding of the windings avoids deformation and damage; 4. The first injection molding uses phenolic or epoxy plastics, and the mold temperature is controlled at 70℃-90℃. The second injection molding, through the venting hole design, ensures the density of the insulation layer, reduces the generation of air holes, and further enhances the insulation performance; 5. The integrated molding of the stator core insulation structure and the tight fit between the windings and the core of this invention reduce winding loosening and wear caused by vibration, improve the mechanical strength and fatigue resistance of the stator assembly, avoid insulation damage caused by exposed windings, avoid the risk of short circuits in the windings, extend the service life of the motor, and improve the quality of the product. Attached Figure Description

[0016] Figure 1 This is a front view of the flat wire stator assembly of the present invention.

[0017] Figure 2 This is a top view of the flat wire stator assembly of the present invention.

[0018] Figure 3 This is a perspective view of the flat wire stator assembly of the present invention.

[0019] Figure 4 This is a perspective view of the stator core of the present invention.

[0020] Figure 5This is a perspective view of insulator one and insulator two of the flat wire stator assembly of the present invention.

[0021] Figure 6 This is a perspective view of insulator three and insulator four of the flat wire stator assembly of the present invention.

[0022] Figure 7 This is a perspective view of the flat wire winding of the present invention.

[0023] Figure 8 This is a three-dimensional view of the stator core and flat wire winding structure of the present invention.

[0024] Figure 9 This is a diagram showing the unfolded shape of the flat wire winding of the present invention.

[0025] Figure 10 This is a schematic diagram of a manufacturing method for a flat wire stator assembly that is injection molded at the bottom and end of the stator core slot according to the present invention.

[0026] Explanation of reference numerals: 1-Stator core, 2-Yoke, 3-Tooth, 4-Tooth groove, 5-Insulator I, 6-Insulator II, 7-Flat wire wave-wound conductor winding, 8-Insulator III, 9-Insulator IV, 10-Terminal, 11-Inlet conductor section, 12-Outlet conductor section, 13-S-shaped wave wire, 14-Offset winding section. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0028] Example 1, as Figures 1 to 9The diagram illustrates a flat wire stator assembly with injection-molded flat wire at the bottom and ends of the stator core slots. The stator assembly includes a stator core 1, which comprises a yoke 2 and a toothed portion 3. A toothed slot 4 is provided circumferentially on the inner side of the stator core 1. An injection-molded insulator 5 is provided on the inner wall of the bottom of the toothed slot 4. An injection-molded insulator 6 is provided on the inner ring of the two end faces of the toothed portion 3 and the two end faces of the yoke 2. A flat wire corrugated conductor winding 7 is provided within the slot of the insulator 5. An injection-molded insulator 3 8 is provided at both ends of the flat wire corrugated conductor winding 7. An injection-molded insulator 4 9 is provided on the inner ring surface of the toothed slot 4. The insulator 3 8 and the insulator 4 9 are integrally formed. A terminal 10 is provided on the outer end face of the insulator 3 8. The flat wire corrugated conductor winding 7 is configured as a continuous corrugated staggered flat wire winding, with the continuous corrugated staggered flat wire winding starting from the input end. The system comprises a wire section 11, an outgoing wire section 12, and an S-shaped waveform line 13 continuously wound into an S-shape between the incoming wire section 11 and the outgoing wire section 12. The S-shaped waveform line 13 includes an effective side portion for placement within the stator slot, straight sections located outside the slot on both sides, and ends connecting adjacent straight sections. An offset winding section 14 is provided within the S-shaped waveform line 13. The offset winding section 14 is positioned with the wires in each phase wire arranged in an offset manner. The offset winding section 14 is located in the middle of the entire S-shaped waveform line 13. Alternatively, the S-shaped waveform line 13 may have an offset winding section 14 in each unidirectional wave winding spaced apart by one wave winding. Based on the number of slots q distributed per pole per phase, in the wave winding composed of the U, V, and W phase windings, the pitch y1 of the U1 wire in the U phase wire is set as follows: y1 = q × m + (q - 1) In the formula: y represents the pitch. q represents the number of slots distributed per pole per phase. m represents the number of phases. The pitch y of line Ua a Set to: Y a = q × m -1, a is set to 2 to 7. In the V-phase line, the pitch y1ˊ of the V1 line is set as: y1ˊ = q × m + (q-1) The pitch y of line Va a ˊ Set to: Y a ˊ = q × m -1, a is set to 2 to 7. In the W-phase line, the pitch y1″ of the W1 line is set as: y1″ = q × m + (q-1) The pitch y of the Wa line a ˊ Set to: Y a " = q × m -1, 'a' can be set to 2 to 7.

[0029] Example 2, as Figure 1 , Figure 4 , Figure 5 , Figure 10 As shown, a method for manufacturing a flat wire stator assembly with injection molding at the bottom and ends of the stator core slots involves first manufacturing the stator core 1. A silicon steel strip is placed on a cutting machine and cut to a width equal to the axial length of the stator core 1. The cut silicon steel strip is then leveled using a leveling machine. The silicon steel strip is then conveyed to a progressive die for stamping. The silicon steel strip is stamped within the progressive die, such as punching continuous fastening points to facilitate fixing. Grooves are then punched into the silicon steel strip. After stamping, the silicon steel strip is fed into a winding mechanism, where the starting end of the silicon steel strip is fixed to the winding die. The silicon steel strip is wound into a spiral loose semi-finished product with a predetermined number of turns by rotating the winding mold. Then it is cut and separated to form individual spiral units. The spiral units are then placed in the stator core 1 forming mold, so that the snap points and tooth grooves 4 of adjacent silicon steel strips are aligned with each other. By pressing, the silicon steel strip is pressed into stator core 1. During the winding process, the mold is kept rotating at a uniform speed, and the silicon steel strip is continuously wound along the spiral trajectory with a constant tension to form an annular stator core 1 blank. The tension of the silicon steel strip is controlled at 100N to ensure that the interlayer gap of stator core 1 is ≤0.03mm.

[0030] Next, the first injection molding is performed at the bottom of the stator core slot. The stator core 1 is first cleaned to remove surface oil and impurities, ensuring good bonding between the insulation material and the stator core 1 body during injection molding. Then, the stator core 1 is placed into the first injection mold. A first mold core is then inserted into the middle of the stator core 1, with the teeth of the first mold core corresponding to the tooth grooves 4 of the stator core 1. A gap of 0.15mm is maintained between the teeth of the first mold core and the tooth grooves 4 of the stator core 1. A gap of 1mm is maintained between the upper inner ring of the first mold core and the upper inner ring of the stator core 1, and between the lower inner ring of the first mold core and the lower inner ring of the stator core 1. A 1mm gap is set between the molds. The mold is closed, and molten insulating material, such as phenolic plastic or epoxy plastic, is injected into the cavity of mold one. The temperature in mold one is set to 70℃-90℃. The insulating material fills the cavity under pressure, forming an injection-molded insulator 5 on the inner wall of the bottom of the slot 4 of the stator core 1. An injection-molded insulator 6 is formed on the inner ring of the two end faces of the tooth 3 and the two end faces of the yoke 2 of the stator core 1. The pressure in mold one is maintained. After the materials of insulator 5 and insulator 6 cool and solidify, mold one is opened, and the flat wire stator slot bottom injection-molded stator core 1 after the first molding is taken out.

[0031] Third, the flat wire is wound. First, a winding mold matching the structure and size of the stator core slot is prepared. The winding mold is equipped with winding trajectory grooves corresponding to the effective edge portion, straight portion and end portion to ensure accurate forming during the winding of the flat wire. One end of the flat wire is fixed at the wire inlet fixed position of the winding mold as the starting end of the wire inlet conductor portion 11. According to the preset winding trajectory, the conductor is continuously wound into an S-shape on the winding mold to form the effective edge portion, straight portion and end portion. During the winding process, the tension of the conductor is strictly controlled to ensure the tightness and consistency of the winding. The inner wall of the winding trajectory groove on the winding mold is equipped with a wear-resistant coating. The width of the winding trajectory groove is 0.05-0.1mm larger than the thickness of the flat wire. During the winding process, the fit between the flat wire and the inner wall of the winding trajectory groove is not less than 95% to reduce wear during winding and ensure forming accuracy. When continuously winding S-shaped waveform lines, a rotatable guide wheel is set at the end turning position of the winding mold. The contact surface of the guide wheel and the flat wire have an arc-shaped adaptation structure, and the rotation speed of the guide wheel is synchronized with the winding speed to reduce the frictional resistance of the wire when turning at the end and improve the stability of the winding process. According to the setting method of the staggered winding part 14, staggered winding is performed at the corresponding position. When the staggered winding part 14 is set in the middle position of the entire S-shaped waveform, the position of the conductor is adjusted when winding to the middle position so that the conductors in each phase conductor are staggered with each other. When the staggered winding part 14 is set in the same direction wave winding every other wave winding, the conductors are staggered when winding to the corresponding wave winding position. When winding the wave winding composed of U, V, and W three-phase windings, the winding is performed according to the following pitch requirements based on the number of slots q distributed per pole per phase: In the U phase line, the pitch y1 of the U1 line is set as: y1 = q × m + q - 1, where y represents the pitch, q represents the number of slots distributed per pole per phase, and m represents the number of phases; the pitch ya of the Ua line is set as: Ya = q × m - 1, where a is 2 to 7. In the V phase line, the pitch y1ˊ of the V1 line is set as: y1ˊ=q×m +q-1; the pitch yaˊ of the Va line is set as: Yaˊ= q×m -1, where a is 2 to 7.

[0032] In the W phase line, the pitch y1″ of the W1 line is set as: y1″=q×m +q-1; the pitch ya″ of the Wa line is set as: Ya″= q×m -1, where a is 2 to 7.

[0033] After winding to the preset length, the other end of the wire is fixed at the wire outlet fixed position of the winding mold to form the wire outlet part 12, thus completing the winding of the entire winding. After the winding is completed and shaped, it is removed from the winding mold and prepared to be embedded into the slot of the stator core 1.

[0034] Fourth, the flat wire is embedded into mold two. Mold two is set as a positioning mold adapted to the structure of the flat wire winding. Its surface is provided with grooves corresponding to the effective side part and straight part of the S-shaped waveform. The size and shape of the grooves match the various parts of the flat wire winding to ensure that the flat wire winding can be accurately embedded and positioned. In order to accurately embed the flat wire winding, a guide positioning component is used to assist in alignment. The guide positioning component includes a tapered guide part set at the groove entrance end of mold two and limiting bosses on both sides. The taper of the tapered guide part is 15°-30°, and the gap between the limiting bosses and the side of the flat wire winding does not exceed 0.03mm, ensuring that the flat wire winding is accurately embedded into the groove along the preset trajectory. Then, the flat wire winding is removed from the winding mold and embedded into the groove of mold two. In specific operation, the completed flat wire winding is aligned with the groove on the mold two according to the preset orientation, so that the effective edge part is embedded into the corresponding segment of the groove of the mold two, and the straight part is also embedded into the corresponding groove segment. During the embedding process, it is necessary to ensure that the flat wire winding is placed stably and without deviation in the groove of the mold two, and that each part is tightly fitted with the groove, in preparation for the subsequent pressing operation; at the same time, check whether the misaligned winding part 14 of the flat wire winding maintains the correct position in the groove of the mold two, to ensure that its structure is not affected by the embedding process.

[0035] Fifth, the flat wire is pressed into the stator core slots. First, the stator core 1, which has undergone the first injection molding, is transferred to mold three, allowing it to rotate around its own axis. The stator core 1 is controlled to rotate to a preset angle, and the positioning device of mold three positions and fixes it, ensuring that each slot on the stator core 1 is in a position that facilitates receiving the flat wire winding. Then, mold two, which contains the flat wire winding, is placed in the middle of the stator core 1. The position of mold two is adjusted so that the direction and position of the groove on mold two are aligned with the slots on the stator core 1, ensuring that the flat wire winding in mold two can be accurately aligned with the slots of the stator core 1 when pressed in. An extrusion device is set on mold two, which is equipped with a drive mechanism and an extrusion device. The extrusion block, driven by a device, generates a pressing force perpendicular to the groove on mold two, causing it to move perpendicularly to the groove. Once mold two is aligned with the slot of stator core 1, the extrusion device on mold two is activated. The pressure of the extrusion device is monitored in real time by a pressure sensor, with an initial pressure set to 30-50 N. The extrusion device applies a uniform pressing force to the flat wire winding within the groove of mold two. Under the action of the extrusion block, the effective edge portion of the flat wire winding detaches from the groove of mold two and is gradually pressed into the corresponding slot of stator core 1. During the pressing process, the pressure and speed of the extrusion device must be controlled. When the effective edge portion of the flat wire winding enters the slot of stator core 1 to a depth of 1 / 3 of its total length... During this process, the pressure is automatically adjusted to 50-80N, and the pressure application speed is maintained at 2-5mm / s. The pressure should be sufficient to allow the flat wire winding to smoothly enter the slot, while avoiding deformation or damage to the flat wire winding due to excessive pressure. The pressure application speed should be kept stable to ensure that the effective side portion is evenly and accurately embedded in the slot until the effective side portion is completely pressed into the slot. After the flat wire winding is pressed in, check whether the position of the effective side portion in the stator core slot 1 is correct, whether it is tightly fitted with the inner wall of the slot, and whether the straight part and the end maintain a normal structural shape to ensure that subsequent processes can proceed smoothly.

[0036] Sixth, the flat wires at both ends of the stator core are shaped. After pressing the effective edge portion of the flat wire into the groove of stator core 1, the stator core 1 is transferred to mold four, and the flat wires at both ends of stator core 1 are shaped.

[0037] Seventh, the stator core is subjected to secondary injection molding. After the two ends of the stator core 1 are shaped, the stator core 1 is transferred to mold five. Then, mold core two is placed in the middle of the stator core 1, the mold is closed, and molten phenolic plastic is injected into the cavity of mold five. Multiple vent holes are provided on the inner wall of the cavity of mold five. The diameter of the vent holes is 0.2-0.3mm and they are evenly distributed along the circumference of the cavity. The spacing between adjacent vent holes is 15-20mm. This facilitates timely gas discharge during the filling of the cavity by the insulating material, preventing the formation of air holes in the injection molded product. The phenolic plastic fills the cavity under pressure. Insulator three 8 is injection molded around the conductors at both ends of the stator core 1 and in the gap between the slots. The pressure inside mold five is maintained. After the material of insulator three 8 cools and solidifies, mold five is opened, and the flat wire stator core 1 after the second injection molding is taken out.

[0038] Eighth, the heating and shaping process: the stator core 1, after secondary injection molding, is transferred to mold six and heated. The temperature in mold six is ​​set to 140℃-170℃, and the heating time is set to 2 to 5 minutes for curing. After curing, the heated and shaped stator core 1 is placed in mold seven for cooling. A circulating water cooling system is used to rapidly cool mold six, with the cooling water temperature controlled at 15-20℃ and the cooling time at 8-12 minutes, to improve mold turnover efficiency and avoid product deformation due to thermal stress. Finally, the stator core 1 is removed from mold seven, completing the final production process.

[0039] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. For those skilled in the art, several modifications and improvements can be made without departing from the present invention, and these should also be considered to fall within the protection scope of the present invention.

Claims

1. A flat wire stator assembly injection molded at the bottom and end of a stator core slot, the stator assembly comprising a stator core (1), the stator core (1) comprising a yoke (2) and a toothed portion (3), and toothed slots (4) provided in the circumferential direction on the inner side of the stator core (1), characterized in that: An injection-molded insulator one (5) is provided on the inner side wall of the groove bottom of the tooth (4). An injection-molded insulator two (6) is provided on the inner ring of the two end faces of the tooth (3) and the two end faces of the yoke (2). A flat wire wave winding (7) is provided in the groove of the insulator one (5). An injection-molded insulator three (8) is provided at both ends of the flat wire wave winding (7). An injection-molded insulator four (9) is provided on the inner ring surface of the tooth groove (4). The insulator three (8) and the insulator four (9) are integrally formed. A terminal post (10) is provided on the outer end face of the insulator three (8). The flat wire wave winding (7) is set as a flat wire continuous wave winding staggered winding. The flat wire continuous wave winding staggered winding consists of an inlet end conductor part (11), an outlet end conductor part (12), and a conductor part located between the inlet end conductor part (11) and the outlet end conductor. The S-shaped waveform (13) is formed by continuous winding of the parts (12) into an S-shape. The S-shaped waveform (13) includes an effective side part for placement in the stator slot, a straight part located outside the two sides of the slot, and the end connecting the adjacent straight parts. An offset winding part (14) is provided in the S-shaped waveform (13). The offset winding part (14) is arranged with the conductors in each phase conductor in an offset arrangement. The offset winding part (14) is located in the middle of the entire S-shaped waveform (13). Alternatively, the S-shaped waveform (13) is set with an offset winding part (14) in each wave winding of the same direction with a gap of one wave winding. The offset winding part (14) is set according to the number of slots q distributed per pole per phase. In the wave winding composed of the U, V, and W phase windings, the pitch y1 of the U1 line in the U phase line is set as follows: y1 = q × m + (q - 1) In the formula: y represents the pitch. q represents the number of slots distributed per pole per phase. m represents the number of phases. The pitch y of line Ua a Set to: Y a = q × m -1, a is set to 2 to 7. In the V-phase line, the pitch y1ˊ of the V1 line is set as: y1ˊ = q × m + (q-1) The pitch y of line Va a ˊ Set to: Y a ˊ = q × m -1, a is set to 2 to 7. In the W-phase line, the pitch y1″ of the W1 line is set as: y1″ = q × m + (q-1) The pitch y of the Wa line a ˊ Set to: Y a " = q × m -1, 'a' can be set to 2 to 7.

2. A method for manufacturing a flat wire stator assembly injection molded at the bottom and ends of the stator core slots as described in claim 1, characterized in that, The method includes the following steps: Step 1: Stator core manufacturing process: Cut silicon steel strip, then level the cut silicon steel strip with a leveling machine, and then transfer the silicon steel strip to a progressive die stamping mold to stamp the silicon steel strip, punching continuous fastening points on the silicon steel strip, then punching grooves on the silicon steel strip, and then feeding the silicon steel strip into a winding mechanism to wind the silicon steel strip into a spiral loose semi-finished product with a predetermined number of turns, and then pressing it to form a stator core; Step Two: Perform the first injection molding process at the bottom of the stator core slot. Place the stator core into the stator core injection mold one, and then insert the mold core one in the middle of the stator core. The teeth of the mold core one correspond to the teeth of the stator core, and a gap of 0.15-0.22mm is set between the teeth of the mold core one and the teeth of the stator core. A gap of 1-1.5mm is set between the upper inner ring of the mold core one and the upper inner ring of the stator core, and the lower inner ring of the mold core one and the stator core... A gap of 1-1.5mm is set between the lower inner rings. The mold is closed, and the molten insulating material is injected into the cavity of mold one. Insulator one is formed on the inner side wall of the tooth groove bottom of the stator core. Insulator two is formed on the inner ring of the tooth end face and the yoke end face of the stator core. After the materials of insulator one and insulator two have cooled and solidified, mold one is opened and the flat wire stator groove bottom injection molded stator core after the first molding is taken out. Step 3: Flat wire winding process. Prepare the winding mold, which has winding trajectory slots corresponding to the effective edge portion, straight portion, and end, to ensure accurate shaping during flat wire winding. Following the preset winding trajectory, continuously wind the conductor into an S-shape on the winding mold, forming the effective edge portion, straight portion, and end. During winding, strictly control the conductor tension to ensure the tightness and consistency of the winding. Based on the staggered winding section's setting method, perform staggered winding at the corresponding positions. When the staggered winding section is located in the middle of the entire S-shaped waveform, adjust the conductor position at the middle position to ensure staggered arrangement of conductors within each phase. When the staggered winding section is located in the same-direction wave winding every other wave winding, perform staggered winding when winding to the corresponding wave winding position. When winding the wave winding composed of U, V, and W phases, according to the number of slots q distributed per pole per phase, wind according to the following pitch requirements: In the U phase line, the pitch y1 of the U1 line... The pitch is set as: y1 = q × m + (q - 1), where y represents the pitch, q represents the number of slots distributed per pole per phase, and m represents the number of phases; the pitch ya of line Ua is set as: Ya = q × m - 1, where a is 2 to 7; In the V phase line, the pitch y1ˊ of the V1 line is set as: y1ˊ=q×m +(q-1); the pitch yaˊ of the Va line is set as: Yaˊ= q×m -1, where a is 2 to 7; In phase W, the pitch y1″ of line W1 is set as: y1″ = q × m + (q - 1); the pitch ya″ of line Wa is set as: Ya″ = q × m - 1, where a is 2 to 7; After winding to the preset length, the other end of the wire is fixed at the wire outlet fixing position of the winding mold to form the wire outlet part (12), thus completing the winding of the entire winding. Step 4: The process of embedding the flat wire into mold 2. Mold 2 is a positioning mold adapted to the structure of the flat wire winding. Its surface is provided with grooves corresponding to the effective side part and straight part of the S-shaped waveform. The size and shape of the grooves match the various parts of the flat wire winding to ensure that the flat wire winding can be accurately embedded and positioned. The flat wire winding is removed from the winding mold and embedded into the groove of mold 2. Step 5: Pressing the flat wire into the stator core slot: First, the stator core, which has undergone the first injection molding, is transferred to mold three. Then, mold two, which contains the flat wire winding, is placed in the middle of the stator core. The position of mold two is adjusted so that the direction and position of the groove on mold two are aligned with the slots on the stator core. An extrusion device is set on mold two. The extrusion device is equipped with a drive mechanism and an extrusion block. The drive mechanism generates an extrusion force perpendicular to the direction of the groove on mold two, causing the extrusion block to move perpendicular to the direction of the groove on mold two. The extrusion device applies a uniform extrusion force to the flat wire winding in the groove of mold two. Under the action of the extrusion block, the effective edge portion of the flat wire winding is separated from the groove of mold two and gradually pressed into the corresponding slot of the stator core. Step Six: Shaping Process. After pressing the effective edge portion of the flat wire into the stator core slot, transfer the stator core to mold four and shape the flat wires at both ends of the stator core. Step 7: Secondary injection molding process. After the two ends of the stator core are shaped, the stator core is transferred to mold five. Then, mold core two is placed in the middle of the stator core, the mold is closed, and the molten insulating material is injected into the cavity of mold five. The insulating material fills the cavity under pressure. Insulator three is injection molded around the conductors at both ends of the stator core and in the gaps between the slots. The pressure inside mold five is maintained. After the material of insulator three cools and solidifies, mold five is opened, and the flat wire stator injection molded stator core after the second injection molding is taken out. Step 8: Heating and shaping process. The stator core after secondary injection molding is transferred to mold six and heated. The temperature in mold six is ​​set to 140℃-170℃ and the heating time is set to 2 to 5 minutes for curing. Step Nine: Cooling process. Place the heated and shaped stator core into mold seven, then cool it down. Finally, remove the stator core from mold seven.

3. The method for manufacturing a flat wire stator assembly by injection molding at the bottom and ends of the stator core slots according to claim 2, characterized in that: In step one, the mold is kept rotating at a constant speed during the winding process, and the silicon steel strip is continuously wound along the spiral trajectory with constant tension to form an annular stator core blank. The tension of the silicon steel strip is controlled at 50-200N to ensure that the interlayer gap of the stator core is ≤0.03mm.

4. The method for manufacturing a flat wire stator assembly by injection molding at the bottom and ends of the stator core slots according to claim 2, characterized in that: In step two, the insulating material is set as phenolic plastic or epoxy plastic, and the temperature in mold one is set as 70℃-90℃.

5. The method for manufacturing a flat wire stator assembly by injection molding at the bottom and end of the stator core slots according to claim 2, characterized in that: In step three, when continuously winding the S-shaped waveform, the inner wall of the winding track groove on the winding mold is provided with a wear-resistant coating. The width of the winding track groove is 0.05-0.1mm larger than the thickness of the flat wire. During the winding process, the fit between the flat wire and the inner wall of the winding track groove is not less than 95% to reduce wear during winding and ensure forming accuracy.

6. The flat wire winding process according to claim 5, characterized in that, In step three, when continuously winding the S-shaped waveform, a rotatable guide wheel is set at the end of the winding mold one at the turning position. The contact surface of the guide wheel and the flat wire have an arc-shaped fitting structure, and the rotation speed of the guide wheel is synchronized with the winding speed.

7. The flat wire winding process according to claim 2, characterized in that, In step four, when the flat wire is embedded into the groove of mold two, a guide positioning component is used to assist in alignment. The guide positioning component includes a tapered guide part set at the entrance end of the groove of mold two and limiting bosses on both sides. The taper of the tapered guide part is 15°-30°, and the gap between the limiting bosses and the side of the flat wire winding does not exceed 0.03mm.

8. The flat wire winding process according to claim 2, characterized in that, In step five, during the process of pressing the flat wire into the stator core slot, the pressure of the pressing device is monitored in real time by a pressure sensor. The initial pressure is set to 30-50N. When the effective side of the flat wire winding enters the stator core slot to a depth of 1 / 3 of its total length, the pressure is automatically adjusted to 50-80N, and the pressing speed is maintained at 2-5mm / s until the effective side is completely pressed into the slot.

9. The flat wire winding process according to claim 2, characterized in that, During the second injection molding process in step seven, multiple vent holes are provided on the inner wall of the cavity of mold four. The diameter of the vent holes is 0.2-0.3mm, and they are evenly distributed along the circumference of the cavity. The distance between adjacent vent holes is 15-20mm.

10. The flat wire winding process according to claim 2, characterized in that, During the cooling and solidification process in step nine, a circulating water cooling system is used to rapidly cool mold six. The cooling water temperature is controlled at 15-20℃, and the cooling time is 8-12 minutes. After cooling, the stator core is smoothly pushed out of mold six using an ejection mechanism.

Images