Semi-closed slot block stator core structure and technological process thereof

Abstract

The invention discloses a semi-closed slot block stator core structure and a technological process thereof. The split type tooth comprises the tooth crown and the tooth, and the tooth crown and the tooth are connected in the mode that the protruding part is embedded into the concave part. In the winding stage, the stator is of an open slot structure, so that enameled wires are convenient to wind, and the winding efficiency and the slot fullness rate are improved. After winding is completed, the tooth crowns are inserted into the teeth, so that the stator is restored to be of a semi-closed slot structure, the problem of performance reduction caused by an open slot structure is avoided, and meanwhile the enameled wires are protected against damage. According to the structure, open slot winding is achieved through split design, the slot fullness rate is increased, the semi-closed slot structure is recovered through the combination of the tooth crowns and the teeth, and the motor performance and enameled wire safety are guaranteed. The manufacturing process comprises the steps of silicon steel sheet machining, winding, detection, tooth crown and tooth combination, finished product detection and the like. According to the stator core structure, the operation efficiency and the service life of the motor are effectively improved, and the stator core structure has remarkable technical advantages and application prospects.

Description

Technical Field

[0001] This application relates to the field of motor winding technology, and in particular to a semi-closed slot segmented stator core structure and its manufacturing process. Background Technology

[0002] One of the key technologies for improving the winding efficiency and quality of motors is the use of segmented design and assembly process for the motor stator core. The segmented design and assembly process of the stator core has significant advantages over the traditional integral design in terms of motor winding efficiency: after segmentation, there is no interference from slots, no need for complex tooling assistance, and the effective production time is greatly increased. This advantage is particularly prominent in machine-wound stator cores, making it a key process path for improving production capacity and yield.

[0003] Currently, the production of segmented stator cores typically uses high-permeability silicon steel sheets as the material. The entire core is divided into fan-shaped or arc-shaped modules according to the number of motor slots. The modules are assembled and adapted through structural designs such as dovetail slots and bolt holes. During manufacturing, single-module laminations are processed by stamping or laser cutting. After surface insulation treatment, they are formed by mechanical stacking or welding. The stator silicon steel sheets have rivets to ensure the dimensional accuracy of the core after assembly.

[0004] The slot shape of the stator core is a key factor affecting winding efficiency. While open slots facilitate coil embedding, they have significant drawbacks. The wide slot opening exacerbates the non-uniformity of air gap magnetic reluctance, generating stronger tooth harmonic magnetic fields, leading to increased stator iron losses and rotor eddy current losses, and decreased motor efficiency. Semi-closed slots, due to their smaller opening, make hand-winding the stator more difficult and inefficient. Therefore, traditional open and semi-closed slots cannot meet the requirements for stator winding efficiency and motor performance. This necessitates proposing a more efficient stator core configuration that improves winding efficiency without compromising motor performance.

[0005] Existing technology, such as CN118381229A, provides a method for forming closed slots in a motor by segmentation into a closed slot structure. This patent describes a closed slot stator core assembly comprising a core body with straight slot openings and a magnetic wedge clamped onto the core body, closing the straight slot openings. The magnetic wedge clamped onto the core body with the straight slot openings ensures the stator core assembly maintains a closed slot structure. However, while this technology achieves a closed slot structure by embedding the magnetic wedge into the core body with the straight slot openings, reducing the cogging torque, the inner circle of the core body and the inner arc of the magnetic wedge form the stator inner diameter. However, actual assembly and machining result in a difference in the curvature between the magnetic wedge and the core body. This leads to an eccentricity problem in the motor's air gap, resulting in decreased motor performance. Obviously, traditional semi-closed slots cannot be automated due to their narrow slot openings. Relying on manual winding results in high costs, low efficiency, and poor consistency. Furthermore, enlarging the slot opening will cause a decline in motor performance (such as increased leakage flux, reduced efficiency, and increased noise). Summary of the Invention

[0006] Based on this, this application provides a semi-closed slot segmented stator core structure and its manufacturing process. This application proposes a semi-closed slot stator core structure that can solve the winding problem of the stator core and avoid the degradation of motor performance.

[0007] Firstly, a semi-closed slot segmented stator core structure and its manufacturing process are provided. The stator core structure includes a crown and teeth, specifically:

[0008] The crown is made of silicon steel sheet and has protrusions for engaging with the recessed part of the tooth.

[0009] The teeth are also made of silicon steel sheet material and have recesses that match the protrusions of the tooth crown for embedded connection with the tooth crown;

[0010] During the winding stage, the teeth have an open slot structure, which facilitates the winding of enameled wire. After winding is completed, the tooth crown is inserted into the teeth, so that the stator returns to a semi-closed slot structure.

[0011] Optionally, the crown and teeth are manufactured using a lamination forming technology, and tooling fixtures are used during the lamination process to precisely control the position and pressure of the silicon steel sheet to ensure that the protrusions and recesses of the crown and teeth are highly matched in terms of dimensional and positional accuracy.

[0012] Optionally, after the crown is inserted into the tooth to restore the semi-closed groove structure, epoxy resin is used to reinforce the crown.

[0013] Optionally, the enameled wire is wound within the open slot structure of the teeth, and the electrical parameters of the winding are detected after winding is completed; wherein, the electrical parameters include at least three-phase resistance and insulation resistance;

[0014] Secondly, a process flow is provided based on the semi-closed slot segmented stator core structure described in any one of the first aspects, the process flow including:

[0015] Silicon steel sheets are selected as the base material. The tooth crown and teeth are processed by slicing and stamping processes, and the components are manufactured by stacking forming technology. The tooth crown has a protrusion, and the teeth have a recess that matches the protrusion.

[0016] Enamelled wire is wound in the open slot structure of the teeth, and the electrical parameters of the winding are tested after the winding is completed; wherein, the electrical parameters include at least three-phase resistance and insulation resistance;

[0017] The tooth crown is precisely inserted into the tooth, restoring the stator to a semi-closed slot structure. Epoxy resin is used to reinforce the tooth crown, ensuring that it remains stable and does not fall off during motor operation.

[0018] After the stator core structure is assembled, the finished product is inspected to determine the motor performance and the integrity of the enameled wire. The finished product that passes the inspection is put into storage.

[0019] Optionally, during the fabrication of the tooth crown and teeth using the lamination forming technology, tooling fixtures are used to precisely control the position and pressure of the silicon steel sheets to ensure that the shape and position accuracy of the laminated parts meets the design requirements and to avoid dimensional errors caused by uneven force or displacement deviation.

[0020] Optionally, during the winding process of enameled wire, automated winding equipment is used to improve winding efficiency and consistency, and an electrical inspection is performed on the winding after winding to ensure that the enameled wire is free from scratches and wear damage.

[0021] Optionally, the enameled wire winding process includes detailed performance testing of the finished product and destructive testing of the insulation performance of the enameled wire to ensure the quality and reliability of the finished product; if the test fails, rework is carried out.

[0022] Optionally, in the step of inserting the crown into the tooth, a high-precision positioning device is used to ensure the embedding accuracy of the crown and the tooth, so that the protrusion and the recess fit tightly together, and after restoring the semi-closed groove structure, the air gap is uniform and there is no eccentricity.

[0023] Optionally, in the finished product testing step, automated testing equipment is used to conduct comprehensive testing of the motor performance, including at least the motor's efficiency, power factor, noise level, and temperature rise index.

[0024] Compared to traditional technologies, the semi-closed slot structure proposed in this application exhibits significant technological innovation and practical advantages. Its core innovation lies in the use of a split silicon steel sheet design for the stator core. By separating the tooth crown and the tooth itself, and employing a precision connection structure where the protrusion is embedded into the recess, a stable connection between the tooth crown and the tooth is achieved. The beneficial effects of the provided technical solution include at least the following:

[0025] From a winding process perspective, this separate design brings revolutionary improvements. During the winding stage, the stator features an open slot structure, which significantly expands the operating space compared to traditional closed or semi-closed slots. This substantially reduces the difficulty of stator unwinding, making the winding process more convenient and efficient, effectively shortening the production cycle and improving production efficiency. Simultaneously, the open slot structure allows the enameled wire to be arranged more tightly and neatly within the slots, effectively increasing the slot fill factor. A higher slot fill factor means that more enameled wire can be accommodated within the same stator space, thereby improving the motor's electromagnetic performance and increasing its output power and torque density.

[0026] After the winding process is completed, the tooth crown is precisely inserted into the tooth, restoring the stator to a semi-closed slot structure. This design cleverly avoids the problems of increased magnetic resistance and decreased electromagnetic performance caused by the increased air gap in traditional open slot structures, ensuring that the motor can maintain excellent operating performance and effectively improving the motor's efficiency and power factor.

[0027] In addition, the insertion of the tooth crown fills the gap in the opening slot, avoiding scratches and wear on the enameled wire during the unwinding process due to the narrow slot opening. This greatly improves the integrity and insulation performance of the enameled wire, reduces the risk of short circuit faults caused by enameled wire damage during motor operation, and significantly improves the reliability and service life of the motor.

[0028] In summary, this application has achieved breakthroughs in multiple dimensions, including improving production efficiency, enhancing motor performance, and ensuring product quality, through structural innovation and process optimization. It has significant technical advantages and broad application prospects. Attached Figure Description

[0029] To more clearly illustrate the embodiments of this application or the technical solutions in 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 merely exemplary, and those skilled in the art can derive other embodiments based on the provided drawings without creative effort.

[0030] Figure 1 A semi-closed slot segmented stator core structure diagram provided in this application embodiment;

[0031] Figure 2A process flow diagram provided for embodiments of this application;

[0032] Figure labels: 1-crown, 2-tooth. Detailed Implementation

[0033] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0034] In the description of this application, the terms "comprising," "having," and any variations thereof are intended to cover non-exclusive inclusion, such as a process, method, system, product, or apparatus that includes a series of steps or units, not necessarily limited to those steps or units that are expressly listed, but may also include other steps or units that are not expressly listed but are inherent to these processes, methods, products, or apparatuses, or steps or units added based on further optimizations conceived in this application.

[0035] To facilitate understanding of this embodiment, a detailed description of a semi-closed slot segmented stator core structure and its manufacturing process disclosed in this application embodiment will be provided first.

[0036] Traditional semi-closed slot stator cores cannot be automated due to their narrow slot openings. Relying on manual winding results in high costs, low efficiency, and poor consistency. Furthermore, enlarging the slot opening can lead to a decline in motor performance (such as increased leakage flux, reduced efficiency, and increased noise). The purpose of this application is to address these problems by proposing a semi-closed slot stator core structure that solves the stator core winding problem while avoiding a decline in motor performance.

[0037] Figure 1 This is a process flow diagram of the technical solution in this application. (For example...) Figure 1 As shown, the stator core structure includes: a split tooth crown 1, which is made of silicon steel sheet material and has a protrusion for engaging with the recessed part of the tooth 2;

[0038] The split tooth 2 is also made of silicon steel sheet material and has a recessed part that matches the protrusion of the tooth crown 1 to achieve the embedded connection with the tooth crown. The tooth 2 has an open slot structure during the winding stage, which facilitates the winding of enameled wire. After the winding is completed, the tooth crown 1 is inserted into the tooth 2, so that the stator returns to a semi-closed slot structure to balance winding efficiency and motor performance.

[0039] Specifically, tooth crown 1 and tooth 2 are connected by a protrusion embedded in a recess. The enameled wire is wound in the stator slots, and the structural design of the stator core provides space for the enameled wire. The open slot winding is achieved through a split structure to improve the slot fill factor, and the combination of tooth crown and tooth restores the semi-closed slot structure, ensuring motor performance and the safety of the enameled wire.

[0040] like Figure 2 As shown, the process flow of a semi-closed groove structure proposed in this application includes the following steps:

[0041] (1) In the manufacturing process of the split crown and teeth, silicon steel sheets are selected as the base material, processed by slicing and stamping processes, and the components are made by stacking forming technology. Given that the crown and teeth adopt a precision connection structure with protrusions embedded in recesses, in order to ensure that the shape and position accuracy of the stacked components meets the design requirements, tooling fixtures are required to accurately control the position and pressure of the silicon steel sheets during the stacking process, effectively avoiding dimensional errors caused by uneven force or displacement deviation, thereby ensuring that the protrusions and recesses of the crown and teeth are highly matched in terms of dimensional and positional accuracy, laying a solid foundation for the subsequent formation of a stable stator core structure through embedded connection.

[0042] (2) Under the open slot structure, the winding is wound on the teeth. After winding, the electrical parameters such as the three-phase resistance and insulation resistance of the winding are tested.

[0043] (3) After winding, the tooth crown is first precisely inserted into the tooth to restore the semi-closed slot structure of the stator; then epoxy resin is used to reinforce the split tooth crown to ensure that it is stable and does not fall off during the motor movement.

[0044] (4) After completing the stator core structure assembly, the finished product is inspected to determine the motor performance and the integrity of the enameled wire. The qualified finished products are put into the warehouse.

[0045] In an optional embodiment of this application, the silicon steel sheet is first processed to create separate tooth crowns and teeth. Then, enameled wire is wound using an open slot structure. After winding, the stator is inspected; if it fails, the winding is readjusted until it passes. Once qualified, the tooth crown is embedded into the teeth through a structure of protrusions and recesses, completing the stator core structure assembly. Finally, the finished product is inspected to determine the motor performance and the integrity of the enameled wire. Qualified finished products are stored in the warehouse, while unqualified products are reworked.

[0046] The core highlight of this application lies in the groundbreaking use of split silicon steel sheets in the stator core, separating the tooth crown and the tooth, and constructing an innovative semi-closed slot structure through the connection method of embedding the protrusion into the recess. This design makes the stator present an open slot shape during winding, which not only significantly reduces the difficulty of unwinding and improves winding efficiency, but also increases the slot fill factor and enhances the electromagnetic performance of the motor. After unwinding, the tooth crown is inserted to restore the semi-closed slot, which avoids the performance degradation caused by the open slot and prevents damage to the enameled wire due to the slot being too narrow. It takes into account both motor performance and reliability, effectively improves operating efficiency and service life, and breaks through the limitations of traditional core design.

[0047] Compared to traditional technologies, the semi-closed slot structure proposed in this application exhibits significant technological innovation and practical advantages. Its core innovation lies in the stator core's use of a split silicon steel sheet design. By separating the tooth crown and the tooth itself, and employing a precision connection structure where protrusions are embedded into recesses, a stable connection between the tooth crown and the tooth is achieved. From a winding process perspective, this split design brings a revolutionary improvement. During the winding stage, the stator presents an open slot structure, significantly expanding the operating space compared to traditional closed or semi-closed slots. This significantly reduces the difficulty of stator unwinding, making the winding process more convenient and efficient, effectively shortening the production cycle and improving production efficiency. Simultaneously, the open slot structure allows the enameled wire to be arranged more tightly and neatly within the slots, effectively increasing the slot fill factor. A higher slot fill factor means that more enameled wire can be accommodated within the same stator space, thereby improving the motor's electromagnetic performance and increasing its output power and torque density. After completing the winding process, the tooth crown is precisely inserted into the tooth, restoring the stator to a semi-closed slot structure. This design cleverly avoids the problems of increased magnetic resistance and decreased electromagnetic performance caused by the increased air gap in traditional open-slot structures, ensuring that the motor maintains excellent operating performance and effectively improving the motor's efficiency and power factor. Furthermore, the insertion of the tooth crown fills the gap in the open slot, preventing scratches and wear on the enameled wire during the unwinding process due to the narrow slot opening. This greatly improves the integrity and insulation performance of the enameled wire, reduces the risk of short circuits caused by wire breakage during motor operation, and significantly enhances the motor's reliability and service life. In summary, this application, through structural innovation and process optimization, achieves breakthroughs in multiple dimensions, including improving production efficiency, enhancing motor performance, and ensuring product quality, demonstrating significant technical advantages and broad application prospects.

[0048] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0049] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A semi-closed slot segmented stator core structure, characterized in that, The stator core structure includes a crown and teeth, specifically: The crown is made of silicon steel sheet and has protrusions for engaging with the recessed part of the tooth. The teeth are also made of silicon steel sheet material and have recesses that match the protrusions of the tooth crown for embedded connection with the tooth crown; During the winding stage, the teeth have an open slot structure, which facilitates the winding of enameled wire. After winding is completed, the tooth crown is inserted into the teeth, so that the stator returns to a semi-closed slot structure.

2. The semi-closed slot segmented stator core structure according to claim 1, characterized in that, The crown and teeth are manufactured using a lamination forming technology. During the lamination process, tooling fixtures are used to precisely control the position and pressure of the silicon steel sheets to ensure that the protrusions and recesses of the crown and teeth are highly matched in terms of dimensional and positional accuracy.

3. The semi-closed slot segmented stator core structure according to claim 1, characterized in that, After the crown is inserted into the tooth to restore the semi-closed groove structure, epoxy resin is used to reinforce the crown.

4. The semi-closed slot segmented stator core structure according to claim 1, characterized in that, The enameled wire is wound in the open slot structure of the tooth, and the electrical parameters of the winding are tested after the winding is completed; wherein, the electrical parameters include at least the three-phase resistance and the insulation resistance.

5. A process flow based on the semi-closed slot segmented stator core structure according to any one of claims 1-4, characterized in that, The specific process flow includes: Silicon steel sheets are selected as the base material. Split tooth crowns and teeth are processed by slicing and stamping processes, and the components are manufactured by stacking forming technology. The tooth crown has protrusions, and the teeth have recesses that match the protrusions. Enamelled wire is wound in the open slot structure of the teeth, and the electrical parameters of the winding are tested after the winding is completed; wherein, the electrical parameters include at least three-phase resistance and insulation resistance; The tooth crown is precisely inserted into the tooth, restoring the stator to a semi-closed slot structure. Epoxy resin is used to reinforce the tooth crown, ensuring that it remains stable and does not fall off during motor operation. After the stator core structure is assembled, the finished product is inspected to determine the motor performance and the integrity of the enameled wire. The finished product that passes the inspection is put into storage.

6. The process flow of the semi-closed slot segmented stator core structure according to claim 5, characterized in that, In the process of fabricating split tooth crowns and teeth using lamination technology, tooling fixtures are used to precisely control the position and pressure of silicon steel sheets to ensure that the shape and position accuracy of the laminated parts meet the design requirements and avoid dimensional errors caused by uneven force or displacement deviation.

7. The process flow of the semi-closed slot segmented stator core structure according to claim 5, characterized in that, During the winding process of enameled wire, automated winding equipment is used to improve winding efficiency and consistency. After the winding is completed, an electrical inspection is performed on the winding to ensure that the enameled wire is free from scratches and wear damage.

8. The process flow of the semi-closed slot segmented stator core structure according to claim 7, characterized in that, The process of winding enameled wire includes detailed performance testing of the finished product and destructive testing of the insulation performance of the enameled wire to ensure the quality and reliability of the finished product; if the test fails, rework is required.

9. The process flow of the semi-closed slot segmented stator core structure according to claim 5, characterized in that, In the step of inserting the crown into the tooth, a high-precision positioning device is used to ensure the embedding accuracy of the crown and the tooth, so that the protrusion and the recess fit tightly. After restoring the semi-closed groove structure, the air gap is uniform and there is no eccentricity.

10. The process flow of the semi-closed slot segmented stator core structure according to claim 5, characterized in that, In the finished product testing step, automated testing equipment is used to conduct comprehensive testing of the motor performance, including at least the motor's efficiency, power factor, noise level, and temperature rise index.

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