Stator assembly, electric machine and compressor

Abstract

The application discloses a kind of stator assembly, motor and compressor, it is related to compressor technical field, wherein, stator assembly includes stator core, winding, second lead-out wire and connecting piece, winding has multiple first lead-out wire, the wire diameter of first lead-out wire is D1;The wire diameter of second lead-out wire is D2;Wire slot includes limiting section and positioning section along the first direction distribution, the width of limiting section is W1, the width of positioning section is W2;Wherein, W1, W2, D1 and D2 satisfy: W1 < W2, D1 ≤D2, and 0.5D2 ≤W1 ≤D1-0.1.The application is designed to include limiting section and positioning section by wire slot, and limit W1 < W2, D1 ≤D2, and 0.5D2 ≤W1 ≤D1-0.1, avoid the problem that first lead-out wire and second lead-out wire are loose or fall off due to plastic expansion of wire slot plastic expansion, improve the stability of motor manufacturing process.

Description

Technical Field

[0001] This invention relates to the field of compressor technology, and in particular to a stator assembly, a motor, and a compressor. Background Technology

[0002] Currently, in compressor motors, the connection methods for motor lead wires are divided into direct lead type and crimped type. Among them, the crimped lead wire connects the conductors of the three-phase windings to the conductors of the external integrated lead wire through the wire groove on the stator insulation end plate.

[0003] The diameter of existing wire guide grooves is generally designed to be the same as the diameter of the pressed-in wire. However, since the surface of the wire is covered with an enameled insulation layer, the actual wire diameter will be slightly larger than the designed diameter of the wire guide groove. During the pressing process, the wire guide groove will be squeezed, causing the wire guide groove to expand and produce plastic deformation. After the groove opening is enlarged, the wire may not be able to be clamped tightly, which may lead to the problem of loosening or even falling off the lead wire in subsequent processes, affecting the stability of the motor manufacturing process. Summary of the Invention

[0004] The main objective of this invention is to provide a stator assembly, motor, and compressor that aims to improve the stability of the motor manufacturing process.

[0005] To achieve the above objectives, the stator assembly proposed in this invention includes:

[0006] Stator core;

[0007] A winding is wound on the stator core, and the winding has a plurality of first leads, the diameter of which is D1;

[0008] The second lead is used to connect the first lead and the external circuit, and the wire diameter of the second lead is D2;

[0009] A connector is provided on the stator core. The connector has a terminal cavity. The cavity wall of the terminal cavity has multiple wire passage slots. The first lead wire and the second lead wire are inserted into the corresponding wire passage slots along the first direction.

[0010] The wire guide groove includes a limiting segment and a positioning segment distributed along the first direction. The positioning segment is disposed near the bottom of the wire guide groove. The width of the limiting segment is W1, and the width of the positioning segment is W2.

[0011] Among them, W1, W2, D1 and D2 satisfy: W1 < W2, D1 ≤ D2, and 0.5D2 ≤ W1 ≤ D1 - 0.1.

[0012] In one embodiment, the groove sidewall corresponding to the limiting segment is elastic and can undergo elastic deformation when the first lead wire or the second lead wire is pressed in along the first direction.

[0013] In one embodiment, the elastic deformation of the groove sidewall corresponding to the limiting segment is T, where T≤D1-0.1.

[0014] In one implementation, W2 satisfies: 0.2≤W1 / W2≤0.8; and / or, D2≤W2≤1.36D1.

[0015] In one embodiment, the cross-section of the groove sidewall corresponding to the positioning segment, cut by a plane extending along the first direction, is either straight or arc-shaped.

[0016] In one embodiment, the groove sidewall and groove bottomwall corresponding to the positioning segment are connected by a first rounded corner, and the minimum radius R of the first rounded corner satisfies: R≥0.5D1.

[0017] In one embodiment, the cable tray further includes a guide section located at one end of the limiting section away from the positioning section, and the width of the guide section gradually decreases in the direction toward the positioning section.

[0018] In one embodiment, the maximum width of the guide segment is W3, where W3 satisfies: W3≥1.5D2.

[0019] In one embodiment, the included angle formed by the two groove sidewalls corresponding to the guide section is θ, where θ satisfies: 30°≤θ≤120°.

[0020] In one embodiment, the guide segment and the limiting segment are connected by a second rounded corner transition.

[0021] In one embodiment, the length of the limiting segment along the first direction is L1, the length of the positioning segment along the first direction is L2, and the sum of the lengths of the limiting segment, the positioning segment, and the guide segment along the first direction is L. L1, L2, and L satisfy: L1+L2≥0.7L, and L1≥0.5L, L2≥1.2D2.

[0022] In one embodiment, the thickness of the cavity wall of the terminal cavity is t, which satisfies: 0.2D1≤t≤0.8D2.

[0023] The present invention also proposes an electric motor including the aforementioned stator assembly.

[0024] The present invention also proposes a compressor, including the aforementioned motor.

[0025] The technical solution of this invention designs the wire groove to include a limiting section and a positioning section, and limits the width W1 of the limiting section and the width W2 of the positioning section to satisfy W1 < W2, D1 ≤ D2, and 0.5D2 ≤ W1 ≤ D1 - 0.1. This allows the first or second lead wire to smoothly pass through the narrower limiting section and enter the wider positioning section during the pressing process in the first direction. When subjected to reverse force, since the diameters of the first and second lead wires are both greater than the width of the limiting section, the first and second lead wires are prevented from coming off. This avoids the problem of the first and second lead wires loosening or falling off due to plastic deformation caused by plastic expansion of the wire groove, and improves the stability of the motor manufacturing process. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0027] Figure 1 This is a top view of an embodiment of the stator assembly provided by the present invention;

[0028] Figure 2 for Figure 1 Side view of the stator component in the middle;

[0029] Figure 3 for Figure 1 A cross-sectional view of the connector assembled with the first lead and the second lead;

[0030] Figure 4 for Figure 3 A partial schematic diagram of the wire groove of the connector in the diagram;

[0031] Figure 5 for Figure 1 Top view of the connector in the middle;

[0032] Figure 6 for Figure 5 A partial schematic diagram of the wire groove of the connector in the diagram;

[0033] Figure 7 The graph shows the effect of W1 / W2 on contact resistance and manufacturing defect rate.

[0034] Explanation of icon numbers:

[0035] 100. Stator core; 200. First lead wire; 300. Second lead wire; 400. Connector; 410. Terminal cavity; 420. Wire groove; 421. Limiting section; 422. Positioning section; 423. Guide section; 424. First fillet; 425. Second fillet.

[0036] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0037] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0038] It should be noted that if the embodiments of the present invention involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indicators will also change accordingly.

[0039] Furthermore, if the embodiments of this invention involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the use of "and / or" or "and / or" throughout the text includes three parallel solutions. For example, "A and / or B" includes solution A, solution B, or a solution where both A and B are satisfied simultaneously. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0040] This invention proposes a stator assembly.

[0041] Please see Figures 1 to 5In one embodiment of the present invention, the stator assembly includes a stator core 100, a winding, a second lead 300, and a connector 400. The winding is wound on the stator core 100 and has a plurality of first leads 200, the wire diameter of which is D1. The second leads 300 are used to connect the first leads 200 and an external circuit, and the wire diameter of which is D2. The connector 400 is disposed on the stator core 100 and has a terminal cavity 410. The wall is provided with multiple wire passage grooves 420. The first lead wire 200 and the second lead wire 300 are inserted into the corresponding wire passage grooves 420 along the first direction. The wire passage groove 420 includes a limiting section 421 and a positioning section 422 distributed along the first direction. The positioning section 422 is located near the bottom of the wire passage groove 420. The width of the limiting section 421 is W1, and the width of the positioning section 422 is W2. Among them, W1, W2, D1 and D2 satisfy: W1 < W2, D1 ≤ D2, and 0.5D2 ≤ W1 ≤ D1 - 0.1.

[0042] Specifically, the stator core 100 is the main structure of the motor stator, composed of multiple stacked silicon steel sheets, used to form the motor's magnetic circuit. The windings are coils wound on the stator core 100, with a first lead 200 extending from its end. The first lead 200 has a wire diameter of D1 and is typically a wire with enameled insulation. The second lead 300 is a cable or connector used to connect the first lead 200 to the compressor's external circuitry, achieving electrical connection between the motor's internal windings and the external power supply; its wire diameter is D2.

[0043] The connector 400 is an insulating component mounted on the stator core 100, such as an insulating end plate or terminal block. It has a terminal cavity 410 inside, used to accommodate crimped terminals (not shown) and provide insulation protection for electrical connections. The cavity wall of the terminal cavity 410 has multiple wire-passing grooves 420. The first lead 200 and the second lead 300 are inserted into their respective wire-passing grooves 420 along a first direction (i.e., the pressing direction from the groove opening to the groove bottom) to achieve positioning and guidance of the first lead 200 or the second lead 300. The wire guide 420 is divided into a limiting section 421 and a positioning section 422 along the first direction. The positioning section 422 is located near the bottom of the wire guide 420 and has a width of W2. It is used to stably support and position the first lead wire 200 or the second lead wire 300 that has been pressed in. The limiting section 421 is located in the area near the opening of the groove and has a width of W1. It is used to prevent the first lead wire 200 or the second lead wire 300 from coming out of the wire guide 420 after assembly.

[0044] In one implementation, please refer to Figure 5The connector 400 includes an outer side plate, an inner side plate, and multiple insulating teeth connecting the inner and outer side plates. The outer side plate and the inner side plate enclose a terminal cavity 410. The insulating teeth are spaced apart along the length of the terminal cavity 410 to divide the terminal cavity 410 into multiple sub-cavities. Each sub-cavity has a wire-passing groove 420 formed on the outer side plate and the inner side plate corresponding to each sub-cavity, and the wire-passing grooves 420 on the corresponding outer side plate and the inner side plate of each sub-cavity are opposite to each other. Each connector 400 has the same number of first leads 200 and second leads 300. (See also...) Figure 3 The first lead 200 and the second lead 300 on the same connector 400 are pressed into different wire slots, and then the crimping terminal is inserted to achieve connection.

[0045] Please refer to Figure 3 and Figure 4 The wire diameter D1 of the first lead 200 and the wire diameter D2 of the second lead 300 can be measured using a digital micrometer or a high-precision vernier caliper. The following measurement is performed using the first lead 200 as an example: Gently clamp the measuring face of the micrometer onto the first lead 200, ensuring the measuring face is perpendicular to the axis of the first lead 200. Slowly rotate the force-measuring device of the micrometer until a "click" sound is heard (indicating that the standard measuring force has been reached), avoiding excessive force that could flatten the first lead 200; read the value on the display screen or scale. The measurement location includes the outer diameter of the conductor with enameled insulation. Measure at different locations (at least 3 points) on the first lead 200 and take the average value as the representative wire diameter D1 of the first lead 200. Measure the second lead 300 in the same way to obtain the wire diameter D2 of the second lead 300.

[0046] The width W1 of the limiting section 421 and the width W2 of the positioning section 422 can be measured using a video measuring instrument, a tool microscope with a micrometer eyepiece, a high-precision plug gauge, or a high-magnification magnifying glass combined with a standard ruler or digital caliper. The following example uses a video measuring instrument to measure the width W1 of the limiting section 421: Securely mount the connector 400 on the stage of the video measuring instrument; adjust the lens to align with the area of ​​the groove 420 to be measured (limiting section 421), and select an appropriate magnification to ensure the edge of the groove is clearly distinguishable; select a representative area with a basically constant width within the limiting section 421 for measurement; use the edge detection function of the video measuring instrument to automatically or manually capture the clear edges of the inner walls on both sides of the groove 420; the instrument will automatically calculate the distance between the two points, which is the groove width at that location; measure the same limiting section 421 at different locations in the first direction, and take the average value as the width W1 of the limiting section 421. The width of the positioning segment 422 is measured in the same way. For the positioning segment 422 whose groove sidewall extends straight along the first direction, the average value of the groove width measured in the measurement area is taken as the width W2 of the positioning segment 422. For the positioning segment 422 whose groove sidewall is curved, the average value of multiple measurements of the area with the largest width is taken as the width W2 of the positioning segment 422.

[0047] W1 < W2 means that the limiting section 421 is narrower than the positioning section 422. When the first lead wire 200 or the second lead wire 300 is under pressure during the assembly process, it can be smoothly pressed from the limiting section 421 into the positioning section 422. After being pressed into the positioning section 422, it is difficult for the first lead wire 200 or the second lead wire 300 to escape from the limiting section 421 with a smaller width. D1 ≤ D2 means that the wire diameter of the first lead wire 200 can be the same as that of the second lead wire 300 or smaller than that of the second lead wire 300. In this way, the stator assembly can be adapted to different specifications of the first lead wire 200, thereby improving the compatibility of the stator assembly with the first lead wire 200. W1 ≥ 0.5D2 to ensure that the limiting section 421 has sufficient width to ensure its smooth entry. W1 ≤ D1 - 0.1 ensures that the width of the limiting section 421 is less than the diameter of the first lead wire 200 (with a margin of 0.1 mm). When the first lead wire 200 or the second lead wire 300 is pressed in, its diameter is greater than the width of the limiting section 421. Thus, the enamel insulation layer of the first lead wire 200 or the second lead wire 300 deforms at the positioning section 422 and is pressed into the positioning section 422 under the action of pressure. The groove width of the positioning section 422 is larger, so the deformation recovers at the positioning section 422; or, it can also be that when the first lead wire 200 or the second lead wire 300 passes through the limiting section 421, its enamel insulation layer does not deform, but the groove side wall of the limiting section 421 elastically deforms to expand the groove opening of the limiting section 421. After the first lead wire 200 or the second lead wire 300 is smoothly pressed into the positioning section 422, the limiting section 421 recovers its elastic deformation and maintains its initial shape. At this time, the limiting section 421 plays a blocking role on the first lead wire 200 or the second lead wire 300 inserted into the positioning section 422, and finally fixes the corresponding first lead wire 200 and second lead wire 300 in the positioning section 422, thereby avoiding the problem that after the first lead wire 200 or the second lead wire 300 is pressed into the wire slot 420, due to the plastic deformation after the expansion of the wire slot 420, the first lead wire 200 or the second lead wire 300 becomes loose or even falls off, thus improving the stability of the motor manufacturing process.

[0048] The technical solution of the present invention designs the wire groove 420 to include a limiting section 421 and a positioning section 422, and limits the width W1 of the limiting section 421 and the width W2 of the positioning section 422 to satisfy W1 < W2, D1 ≤ D2, and 0.5D2 ≤ W1 ≤ D1 - 0.1. This allows the first lead wire 200 or the second lead wire 300 to smoothly pass through the narrower limiting section 421 and enter the wider positioning section 422 during the pressing process along the first direction. When subjected to reverse force, since the diameters of the first lead wire 200 and the second lead wire 300 are both larger than the width of the limiting section 421, the first lead wire 200 and the second lead wire 300 are prevented from coming off. This avoids the problem of the first lead wire 200 and the second lead wire 300 loosening or falling off due to plastic deformation caused by the plastic expansion of the wire groove 420, and improves the stability of the motor manufacturing process.

[0049] In one implementation, please refer to Figure 4 The groove sidewall corresponding to the limiting section 421 is elastic and can undergo elastic deformation when the first lead-out line 200 or the second lead-out line 300 is pressed in the first direction.

[0050] When the first lead 200 or the second lead 300 is pressed into the wire groove 420 along the first direction, since the outer diameter of the first lead 200 and the second lead 300 is greater than the width W1 of the limiting section 421, the first lead 200 and the second lead 300 will exert radial pressure on the sidewall of the groove when passing through the limiting section 421. At this time, the sidewall of the limiting section 421 undergoes elastic deformation outward under the pressure, temporarily expanding the opening of the limiting section 421, thereby allowing the first lead 200 and the second lead 300 to pass through the groove. The second lead wire 300 passes smoothly; after the first lead wire 200 and the second lead wire 300 are fully pressed into the wider positioning section 422, the sidewall of the groove rebounds due to the elastic recovery ability of the material and returns to its initial shape; at this time, the first lead wire 200 or the second lead wire 300 is located in the positioning section 422, and the elastically recovered limiting section 421 forms a mechanical barrier between the positioning section 422 and the groove opening of the wire passage 420, preventing it from coming out under mechanical vibration or the reverse action of the next process.

[0051] Traditional rigid wire guide grooves 420 may undergo plastic deformation under repeated crimping or interference fits, resulting in increased groove width and decreased locking force. However, the elastic deformation of the groove sidewall of the limiting section 421 in this invention is reversible, allowing for flexible expansion during the crimping process. This avoids the problem of loosening or detachment of the first lead wire 200 and the second lead wire 300 due to plastic deformation after the wire guide groove 420's plastic expansion, thus improving the stability of the motor manufacturing process. Simultaneously, it reduces crimping force, preventing damage to the insulation layer of the first lead wire 200 or the second lead wire 300, and improving assembly yield. The elastically restored groove sidewall forms a physical barrier against the crimped first lead wire 200 or the second lead wire 300, making it difficult for them to detach from the limiting section 421 even when subjected to vibration, thermal expansion and contraction, or electromagnetic impact during motor operation. In addition, in actual production, there are slight fluctuations in cable diameter, mold precision, and material shrinkage rate. The sidewall of the elastic groove can automatically adapt to dimensional deviations within a certain range, improving the product's tolerance to manufacturing tolerances and reducing the defect rate.

[0052] In other embodiments, the enameled insulation layers of the first lead 200 and the second lead 300 may have a large thickness, so that when the first lead 200 and the second lead 300 pass through the limiting section 421, their enameled insulation layers can generate a large elastic deformation, so that the first lead 200 and the second lead 300 can pass smoothly through the limiting section 421.

[0053] In one embodiment, the elastic deformation of the groove sidewall corresponding to the limiting segment 421 is T, where T≤D1-0.1.

[0054] The elastic deformation T refers to the recoverable deformation in one side or the total width direction of the groove sidewall of the limiting section 421 caused by the outward expansion of the first lead 200 or the second lead 300 under radial pressure when the first lead 200 or the second lead 300 is pressed into the limiting section 421 along the first direction. This deformation T mainly depends on the elastic modulus of the material of the connector 400, the groove wall thickness, and the structural design. On the one hand, by limiting T ≤ D1-0.1, it is ensured that the groove sidewall of the limiting section 421 has sufficient elastic deformation capacity, so that the first lead 200 or the second lead 300 can be smoothly pressed into the positioning section 422, avoiding scratches or crushing of the enameled wire insulation layer due to rigid interference. On the other hand, it can prevent material fatigue or local stress concentration caused by excessive deformation of the groove sidewall of the limiting section 421, avoid permanent plastic deformation or even cracking of the groove sidewall of the limiting section 421, and ensure the structural integrity and long-term reliability of the connector 400.

[0055] Furthermore, based on the dimensional relationship W1≤D1-0.1, it can be seen that the original width of the limiting segment 421 is significantly smaller than the diameter of the first lead wire 200, and the upper limit of the elastic deformation T corresponds to it. This means that the groove sidewall only needs to undergo moderate elastic expansion to complete the assembly, which not only ensures the feasibility of the pressing process, but also ensures that an effective locking force can be formed after the springback, achieving a self-locking effect that is easy to install and difficult to remove.

[0056] In one implementation, please refer to Figure 4 W2 satisfies: 0.2≤W1 / W2≤0.8; and / or, D2≤W2≤1.36D1.

[0057] The width W2 of the positioning section 422 affects the tightness of the first lead 200 and the second lead 300 in the positioning section 422. If the width W2 of the positioning section 422 is too wide, the first lead 200 or the second lead 300 may become loose, resulting in poor contact between the first lead 200 and the second lead 300, increasing the contact resistance, generating additional heat, causing local temperature rise, and also causing current fluctuations, affecting the normal operation of the motor. If the width W2 of the positioning section 422 is too narrow, the first lead 200 and the second lead 300 will be difficult to fit into the positioning section 422, and may even damage the enameled wire insulation layer of the first lead 200 and the second lead 300, increasing the manufacturing defect rate.

[0058] By controlling the relative dimensions of the width W1 of the limiting section 421 and the width W2 of the positioning section 422 to satisfy 0.2≤W1 / W2≤0.8, a reasonable structural gradient is ensured between them. When W1 / W2≥0.2, it indicates that the limiting section 421 is not too narrow, which is conducive to the smooth passage of the first lead 200 and the second lead 300, avoiding excessive pressing force or excessive deformation of the elastic sidewall due to an insufficient inlet. At the same time, it also indicates that the positioning section 422 is not too wide, which can effectively reduce the risk of loosening of the first lead 200 or the second lead 300, thereby reducing the contact resistance. When W1 / W2≤0.8, it ensures that W2 is significantly larger than W1, forming a sufficient width step to ensure that the first lead 200 or the second lead 300 in the positioning section 422 is difficult to detach in the reverse direction. At the same time, it also indicates that the positioning section 422 is not too narrow, avoiding damage to the enameled wire insulation layer of the first lead 200 and the second lead 300, reducing the manufacturing defect rate. The design of 0.2≤W1 / W2≤0.8 takes into account both the requirements of easy assembly and difficult loosening of the limiting section 421, as well as the requirements of difficult loosening and low damage of the positioning section 422, thereby improving the overall mechanical stability of the through-slot 420 and the safety of motor operation.

[0059] Please see Figure 7The contact resistance of the first lead 200 and the second lead 300 decreases with increasing W1 / W2, and tends to stabilize when W1 / W2 > 0.8. When 0.2 ≤ W1 / W2 ≤ 0.8, the contact resistance is between 2.1 mΩ and 3.2 mΩ, meaning the contact resistance of the first lead 200 and the second lead 300 is relatively low. The contact resistance is lowest at 2.1 mΩ when W1 / W2 = 0.8. The manufacturing defect rate of the first lead 200 and the second lead 300 initially decreases with increasing W1 / W2, and then increases again with increasing W1 / W2 after reaching its lowest point. When 0.2 ≤ W1 / W2 ≤ 0.8, the manufacturing defect rate is between 0.6% and 1.0%. The manufacturing defect rate is lowest at 0.6% when W1 / W2 = 0.6.

[0060] As can be seen, by controlling 0.2≤W1 / W2≤0.8, the risks of loosening and overheating caused by an excessively wide W2 and the assembly damage caused by an excessively narrow W2 are effectively avoided. This ensures the stable fixation of the first lead 200 and the second lead 300 within the positioning section 422, improves the reliability of the electrical connection, and reduces contact resistance. Furthermore, it optimizes the press-in process and reduces the manufacturing defect rate.

[0061] For further details, please refer to Figure 4 By controlling D2≤W2, the width of the positioning section 422 is ensured to be no less than the wire diameter of the second lead 300, providing sufficient space for the first lead 200 and the second lead 300, preventing assembly difficulties or insulation damage due to insufficient clearance, and reducing manufacturing defects. By controlling W2≤1.36D1, the positioning section 422 is limited from being too wide, preventing the first lead 200 and the second lead 300 from wobbling within the positioning section 422. An excessively large W2 would cause the first lead 200 and the second lead 300 to be loosely fixed, easily leading to poor contact and temperature rise problems, thus reducing contact resistance. Furthermore, since the wire diameters D1 of the first lead 200 and D2 of the second lead 300 are both greater than the width W2 of the positioning section 422, the positioning section 422 can accommodate various enameled wires, improving the compatibility of the connector 400 with enameled wires of different diameters.

[0062] By controlling 0.2≤W1 / W2≤0.8 and D2≤W2≤1.36D1, the width W2 of the positioning section 422 is precisely controlled from both relative proportion and absolute dimension perspectives. This effectively avoids the risks of loosening and overheating caused by an excessively wide W2 and the assembly damage caused by an excessively narrow W2. It ensures the stable fixation of the first lead 200 and the second lead 300 within the positioning section 422, improving the reliability of the electrical connection and reducing contact resistance. It also optimizes the press-fit process, reducing the manufacturing defect rate. Simultaneously, this design enhances the stator assembly's adaptability to different wire diameters, facilitating product platformization and standardization, and significantly improving the motor's safety, stability, and manufacturing consistency during long-term operation.

[0063] In one embodiment, the groove sidewall corresponding to the positioning segment 422 has a straight cross-section cut by a plane extending along the first direction.

[0064] The two side walls of the positioning section 422 of the straight groove sidewall are planes extending along the first direction, making the cross-section of the positioning section 422 rectangular or trapezoidal. This structure is simple to process, has precise dimensional control, and facilitates surface contact or near-surface contact with the outer circle of the first lead-out line 200 or the second lead-out line 300. This is beneficial for uniformly transmitting the pressing force and reducing local stress concentration.

[0065] In another implementation, please refer to Figure 4 The groove sidewall corresponding to positioning segment 422 has an arc-shaped cross-section cut by a plane extending along the first direction.

[0066] The sidewall profile of the designated positioning segment 422 of the arc-shaped groove is arc-shaped, and its curvature can match the outer arc of the first lead 200 or the second lead 300 to form an enveloping contact. This structure can better adapt to the circular cross-section of the first lead 200 or the second lead 300, provide more uniform support force during the crimping process, effectively disperse contact stress, prevent the insulation layer from being damaged by point stress, and at the same time have better tolerance to small fluctuations in wire diameter, improving assembly tolerance.

[0067] In one implementation, please refer to Figure 4 The side wall of the groove corresponding to the positioning section 422 is connected to the bottom wall of the groove by a first fillet 424. The minimum radius R of the first fillet 424 satisfies: R≥0.5D1.

[0068] A first rounded corner 424 is provided at the connection between the sidewall and bottom wall of the positioning section 422 to effectively avoid stress concentration problems caused by traditional right-angle structures. When the first lead 200 or the second lead 300 is pressed into the positioning section 422 along the first direction, the contact area between the first lead 200 or the second lead 300 and the bottom and sidewall of the groove will be subjected to a certain amount of compression and friction. If the connection is a sharp right angle, it is not only easy to scratch or tear the enameled insulation layer on the surface of the first lead 200 or the second lead 300 during the pressing process, leading to a decrease in local insulation performance or even a short circuit risk, but the right-angle structure is also prone to stress concentration during injection molding, reducing the mechanical strength of the connector 400 itself, and micro-cracks or fractures may occur during long-term use. By setting the first fillet 424 for a smooth transition, when R≥0.5D1, its curvature is sufficiently gentle, which can effectively guide the first lead wire 200 and the second lead wire 300 to slide smoothly into the bottom of the positioning section 422, reducing frictional resistance and local extrusion during the pressing process; at the same time, a larger fillet radius can make the stress more evenly distributed inside the connector 400, improve the fatigue resistance of the structure, and prevent material cracking caused by repeated assembly or running vibration.

[0069] In one implementation, please refer to Figure 3 and Figure 4 The cable tray 420 also includes a guide section 423, which is located at the end of the limiting section 421 away from the positioning section 422. The width of the guide section 423 gradually decreases in the direction toward the positioning section 422.

[0070] The guide section 423 is located near the opening of the slot 420, and the width of the guide section 423 gradually narrows from the opening to the bottom of the slot. The two opposite sidewalls of the guide section 423 can both form an angle with the sidewall of the limiting section 421, making the guide section 423 trumpet-shaped; or one sidewall of the guide section 423 can form an angle with the corresponding sidewall of the limiting section 421, and the other sidewall of the guide section 423 can be straight to the other corresponding sidewall of the limiting section 421. When the first lead wire 200 or the second lead wire 300 is guided through the wire groove 420 during the crimping process, even if there is a slight positional deviation, the inclined sidewall of the guide section 423 can play an automatic guiding and correcting role, guiding the first lead wire 200 or the second lead wire 300 to smoothly align with the entrance of the limiting section 421, avoiding the first lead wire 200 or the second lead wire 300 from scraping the groove wall or the edge of the connector 400 due to eccentric pressing.

[0071] Furthermore, the tapered structure of the guide section 423 significantly reduces the initial pressing force. In a traditional straight-walled slot design without the guide section 423, the first lead 200 and the second lead 300 must overcome the elastic contraction force or frictional resistance of the entire limiting section 421 instantaneously, which can easily cause a sudden increase in pressing force, leading to excessive equipment load or damage to the enameled insulation layer. However, by setting the guide section 423, the pressing force rises steadily during the pressing process, which is conducive to achieving stable control of the automated pressing process and improving production efficiency and product consistency.

[0072] In one implementation, please refer to Figure 4 The maximum width of guide segment 423 is W3, and W3 satisfies: W3≥1.5D2.

[0073] The maximum width W3 of the guide section 423 is located at the opening of the wire guide groove 420. The maximum width W3 of the guide section 423 determines the space margin when the first lead 200 and the second lead 300 initially enter the wire guide groove 420. By setting W3≥1.5D2, sufficient assembly tolerance of the first lead 200 and the second lead 300 can be effectively ensured. In actual production, especially during automated crimping, there may be slight positional deviations or angular tilts between the first lead 200 and the second lead 300 and the wire guide groove 420. If the opening of the guide section 423 is too small, the first lead 200 and the second lead 300 are prone to hitting the edge of the groove, resulting in damage to their enameled insulation layer or misalignment during crimping. W3≥1.5D2 provides a sufficient alignment window, allowing the first lead 200 or the second lead 300 to be smoothly guided in even with a certain degree of misalignment, significantly reducing the requirements for assembly accuracy and improving production cycle time and yield.

[0074] In one implementation, please refer to Figure 4 The included angle formed by the two sidewalls of the guide section 423 is θ, which satisfies: 30°≤θ≤120°.

[0075] The two opposing side walls of the guide section 423 are inclined inwards. The included angle θ refers to the inner angle formed by the two guide section 423 groove side walls as they extend inwards. If the included angle is too small (e.g., less than 30°), the guide section 423 will become too long and narrow, forming a deep and narrow entrance structure. This will not only increase the difficulty of injection molding but may also cause the first lead wire 200 and the second lead wire 300 to be subjected to excessive lateral pressure in the initial pressing stage, increasing frictional resistance and even causing scratches on the enameled insulation layer. At the same time, an excessively small included angle will narrow the effective guide window, reducing the tolerance for assembly deviations. By limiting θ to ≥ 30°, it is ensured that the guide section 423 has a large unfolding angle, providing sufficient guide space.

[0076] If the included angle is too large (e.g., exceeding 120°), the guide section 423 tends to be flat and wide. Although the entrance is wide, the guiding effect is significantly weakened, and it cannot effectively correct the skewness of the first lead-out line 200 and the second lead-out line 300, thus losing its guiding function. In addition, an excessively large included angle may cause the connector 400 to have a weak structure in the slot area, affecting the overall mechanical strength. By limiting θ ≤ 120°, the guide section 423 can be guaranteed to have sufficient convergence, achieving effective centering and gradual convergence of the first lead-out line 200 and the second lead-out line 300, ensuring a smooth transition to the limiting section 421.

[0077] By limiting the angle to 30°≤θ≤120°, the guide section 423 can achieve a good balance between introduction efficiency and guidance accuracy. This ensures that the first lead wire 200 or the second lead wire 300 can easily enter, and also enables automatic correction through the contact of the inclined wall. This allows the first lead wire 200 or the second lead wire 300 to gradually center itself during the pressing process and accurately enter the subsequent limiting section 421 and positioning section 422, thereby improving assembly consistency.

[0078] In one implementation, please refer to Figure 4 The guide section 423 and the limiting section 421 are connected by a second fillet 425.

[0079] The guide section 423, the limiting section 421, and the positioning section 422 are arranged sequentially along the first direction. The guide section 423 and the limiting section 421 are transitioned by a second rounded corner 425. The second rounded corner 425 is located between the narrowing end of the guide section 423 and the starting end of the limiting section 421, making the change from wide to narrow of the groove sidewall smoother and more continuous. This avoids the formation of obvious steps or sharp corner structures at the intersection of the guide section 423 and the limiting section 421. When the lead wire is pressed in along the first direction, the contact between its surface and the groove wall changes from point contact or line contact to a more uniform surface contact, significantly reducing local pressure and frictional resistance. This avoids scratching, squeezing, or even local damage to the enameled insulation layer of the first lead wire 200 and the second lead wire 300 during the pressing process, which would affect the electrical insulation performance and increase the risk of short circuit. Meanwhile, during the injection molding process of connector 400, the setting of the second fillet 425 also reduces the risk of stress concentration, improves the fatigue resistance and mechanical strength of the material, reduces the occurrence of microcracks or structural fractures in the product during use, and improves the durability of the product.

[0080] In one implementation, please refer to Figure 4 The length of the limiting segment 421 along the first direction is L1, the length of the positioning segment 422 along the first direction is L2, and the sum of the lengths of the limiting segment 421, the positioning segment 422 and the guide segment 423 along the first direction is L. L1, L2 and L satisfy: L1+L2≥0.7L, and L1≥0.5L, L2≥1.2D2.

[0081] The guide section 423 achieves initial insertion and centering, the limiting section 421 achieves anti-detachment locking, and the positioning section 422 provides stable support and crimping space. L1+L2≥0.7L indicates that the total length of the limiting section 421 and the positioning section 422 accounts for more than 70% of the total length of the wire passage 420, demonstrating that the main function of the wire passage 420 is concentrated on locking and fixing the first lead wire 200 and the second lead wire 300, effectively preventing insufficient overall pull-out resistance due to an excessively short locking section, and improving the mechanical stability of the connector 400. L1≥0.5L further emphasizes the dominant position of the limiting section 421 in terms of length. As a key structure preventing the first lead wire 200 and the second lead wire 300 from detaching, the longer size of the limiting section 421 means a larger contact area and stronger blocking ability. After the first lead 200 or the second lead 300 is pressed in, the limiting segment 421 continuously covers the first lead 200 and the second lead 300 along its length. Even under vibration, thermal expansion and contraction, or electromagnetic impact, it can effectively suppress the slight movement or retraction tendency of the first lead 200 and the second lead 300, significantly improving the anti-loosening performance. L2≥1.2D2 is the minimum requirement for the axial length of the positioning segment 422, ensuring that it has sufficient space to accommodate the first lead 200 and the second lead 300 and achieve a reliable connection with the crimping terminal. The positioning segment 422 not only supports the cable but also needs to provide a stable positioning reference for the crimping process. If L2 is too short, the crimping terminal may be partially suspended or have insufficient contact, resulting in weak crimping, increased contact resistance, and consequently, local temperature rise and current fluctuations. Setting L2≥1.2D2 can meet the conventional crimping length requirements while also accommodating a certain range of assembly errors, ensuring the stability and current carrying capacity of the electrical connection. In addition, the L2≥1.2D2 design also improves the compatibility with first lead 200 of different wire diameters or second lead 300 of different wire diameters.

[0082] In one implementation, please refer to Figure 5 and Figure 6 The thickness of the cavity wall of terminal cavity 410 is t, which satisfies: 0.2D1≤t≤0.8D2.

[0083] The wall thickness t of the terminal cavity 410 is the overall thickness of the wire groove 420. The wall thickness t of the terminal cavity 410 directly affects the structural rigidity, deformation resistance, and insulation performance of the connector 400.

[0084] D1 is the wire diameter of the first lead 200. By limiting 0.2D1≤t, the cavity wall of the terminal cavity 410 can be ensured to have sufficient rigidity, preventing destructive plastic deformation after the first lead 200 or the second lead 300 is pressed into the slot 420. It also ensures that the cavity wall of the terminal cavity 410 has sufficient structural strength to withstand the pressure applied during crimping and the vibration load during motor operation, preventing cavity deformation, cracking, or slot wall collapse due to excessive wall thickness, which would affect the geometric accuracy and locking function of the limiting section 421 and the positioning section 422. Simultaneously, a larger wall thickness also helps improve the material flow stability and demolding performance during injection molding, reducing manufacturing defects.

[0085] D2 is the wire diameter of the second lead 300. By limiting t ≤ 0.8D2, excessive rigidity of the wire groove 420 can be avoided, which would prevent the sidewall of the limiting section 421 from elastically deforming when the first lead 200 or the second lead 300 is pressed into the wire groove 420, thus preventing the first lead 200 or the second lead 300 from being pressed into the wire groove 420. It also avoids excessive wall thickness, which would occupy too much space. If the cavity wall is too thick, it would compress the available internal space, limiting the arrangement of the first lead 200 or the second lead 300 and the crimping terminal, which is not conducive to miniaturization design. Furthermore, excessively thick walls may lead to material waste, increased weight, and uneven cooling and shrinkage, affecting product consistency.

[0086] The present invention also proposes an electric motor, which includes a stator assembly. The specific structure of the stator assembly is as described in the above embodiments. Since the present motor adopts all the technical solutions of all the above embodiments, it has at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be described in detail here.

[0087] The present invention also proposes a compressor, which includes a motor. The specific structure of the motor is as described in the above embodiments. Since the compressor adopts all the technical solutions of all the above embodiments, it has at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be described in detail here.

[0088] The above description is merely an exemplary embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention specification and drawings under the technical concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A stator assembly, characterized in that, include: Stator core; A winding is wound on the stator core, and the winding has a plurality of first leads, the diameter of which is D1; The second lead is used to connect the first lead and the external circuit, and the wire diameter of the second lead is D2; A connector is provided on the stator core. The connector has a terminal cavity. The cavity wall of the terminal cavity has multiple wire passage slots. The first lead wire and the second lead wire are inserted into the corresponding wire passage slots along the first direction. The wire guide groove includes a limiting section and a positioning section distributed along the first direction. The positioning section is disposed near the bottom of the wire guide groove. The groove sidewall corresponding to the limiting section is elastic and can elastically deform when the first lead or the second lead is pressed in along the first direction. It is configured to prevent the corresponding first lead or the second lead from coming out in the opposite direction of the first direction after the first lead or the second lead is pressed in by its elastic restoring force. The width of the limiting section is W1, the width of the positioning section is W2, the elastic deformation of the groove sidewall corresponding to the limiting section is T, and the thickness of the cavity wall of the terminal cavity is t. Among them, W1, W2, D1 and D2 satisfy: W1 < W2, D1 ≤ D2, and 0.5D2 ≤ W1 ≤ D1 - 0.1; T satisfies: T≤D1-0.1mm; t satisfies: 0.2D1≤t≤0.8D2.

2. The stator assembly as claimed in claim 1, characterized in that, W2 satisfies: 0.2≤W1 / W2≤0.8; and / or, D2≤W2≤1.36D1.

3. The stator assembly as claimed in claim 1, characterized in that, The groove sidewall corresponding to the positioning section has a straight or arc-shaped cross-section cut by a plane extending along the first direction.

4. The stator assembly as claimed in claim 1, characterized in that, The groove sidewall and groove bottomwall corresponding to the positioning section are connected by a first rounded corner transition, and the minimum radius R of the first rounded corner satisfies: R≥0.5D1.

5. The stator assembly as claimed in claim 1, characterized in that, The cable tray further includes a guide section, which is located at the end of the limiting section away from the positioning section, and the width of the guide section gradually decreases in the direction toward the positioning section.

6. The stator assembly as claimed in claim 5, characterized in that, The maximum width of the guide segment is W3, and W3 satisfies: W3≥1.5D2.

7. The stator assembly as claimed in claim 5, characterized in that, The included angle formed by the two sidewalls of the guide section is θ, and θ satisfies: 30°≤θ≤120°.

8. The stator assembly as claimed in claim 5, characterized in that, The guide section and the limiting section are connected by a second rounded corner transition.

9. The stator assembly as claimed in claim 5, characterized in that, The length of the limiting segment along the first direction is L1, the length of the positioning segment along the first direction is L2, and the sum of the lengths of the limiting segment, the positioning segment and the guide segment along the first direction is L. L1, L2 and L satisfy: L1+L2≥0.7L, and L1≥0.5L, L2≥1.2D2.

10. An electric motor, characterized in that, Includes the stator assembly as described in any one of claims 1 to 9.

11. A compressor, characterized in that, Including the motor as described in claim 10.

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