Manual potting tool and potting method for frameless motor stator

Abstract

The invention discloses a frameless motor stator manual filling and sealing tool and a filling and sealing method. The tool comprises an upper sealing part, a lower sealing part, a sealing cover, a mandrel and a pushing mandrel, the method comprises the following steps: 1) fixing the frameless motor stator to be encapsulated between the upper sealing part and the lower sealing part; (2) after a release agent is sprayed to the mandrel, the mandrel is fixedly installed in the lower sealing part; 3) preheating for a certain time, taking out, and injecting a pouring sealant solution; 4) uniformly spraying a release agent on the outer surface of the pushing mandrel, pushing the flat-bottom blind hole of the mandrel, and injecting the pouring sealant solution into the frameless motor stator to be poured; (5) standing or carrying out defoaming treatment in a vacuum environment, and carrying out glue filling or cleaning treatment according to the potting condition; the method comprises the steps of (1) pouring sealant liquid, (2) pouring sealant liquid, (3) pouring sealant liquid, (4) pouring sealant liquid, (5) pouring sealant liquid, (6) installing and fixing a sealing cover and cleaning overflowing pouring sealant liquid, (7) taking out and cooling after curing for a certain time, and (8) disassembling a pouring tool and cleaning flash and adhesive edges to obtain a frameless motor stator pouring finished product.

Description

Technical Field

[0001] This invention relates to the field of motor potting technology, specifically to a manual potting fixture and potting method for frameless motor stators. Background Technology

[0002] In recent years, the robotics industry has seen a shift in demand for joint motors towards smaller sizes and constant torque, requiring continuously increasing power density. Frameless torque motors, through potting technology, can achieve a more compact design, outputting greater torque within a smaller space. Robots often operate in complex environments, such as humid and dusty conditions. Potting technology provides frameless torque motors with excellent waterproof and dustproof performance, ensuring stable operation under harsh conditions. When a robot performs an action, the motor current increases instantaneously, easily leading to a rapid rise in internal temperature. The potting compound has excellent thermal conductivity, efficiently transferring internal heat to the external heat dissipation structure, reducing motor temperature rise, extending service life, and improving operational stability. The frameless motor stator potting structure is fully open, posing significant challenges to the design of potting tooling and process routes, and making it difficult to guarantee appearance quality and consistency.

[0003] Currently, the conventional stator potting fixture structure mainly consists of a mandrel and a base. The operation process is as follows: assembling the stator with the mandrel and base → preheating → potting compound injection → vacuum degassing → curing. Through actual process verification, when the stator slot fill factor is approximately 68%, slowly pouring 1 kg of potting compound with a density of 1.9 g / ml into the upper part of the stator coil, and then degassing under vacuum to allow the potting compound to penetrate into the stator coil until the liquid surface stabilizes, requires ≥1 hour. However, the higher the density of the potting compound, the longer the potting time will be, or it may not penetrate at all. Furthermore, based on the characteristics of commonly available potting compounds, after the mixed potting compound has stood for 1 hour, a dry film will form on the surface, and it will gradually solidify naturally over time, reducing the fluidity of the compound and hindering its penetration. The main characteristics of frameless motors are a high slot fill factor (≥70%) and strict requirements for the appearance quality of the potting. Traditional potting tooling and methods cannot guarantee the potting quality and consistency. Secondly, there is a large degree of human variation, which can easily cause damage to the frameless stator before and after potting, resulting in a high risk of stator scrapping. Summary of the Invention

[0004] The purpose of this invention is to provide a tooling and method for manual potting of frameless motor stators.

[0005] The technical solution adopted to achieve the technical objective of this invention is as follows: a frameless motor stator manual potting fixture, comprising: an upper sealing part, a lower sealing part, a sealing cover, a mandrel, and a push mandrel.

[0006] The upper sealing part has a columnar structure.

[0007] The upper sealing part has a stepped through hole at its center, and a number of countersunk through holes and threaded through holes I are uniformly arranged around the stepped through hole.

[0008] The stepped through hole is a two-stage stepped hole, wherein the second stage is adapted to the stator of the frameless motor to be potted.

[0009] The countersunk holes and threaded holes I are spaced apart.

[0010] The lower sealing part is a two-stage stepped columnar structure, wherein the center of the smaller diameter first-stage step is provided with a through hole I, and the center of the larger diameter first-stage step is provided with a stepped inner hole.

[0011] The through hole I and the stepped inner hole are connected, and the diameter of the connecting opening is smaller than the diameter of the through hole I.

[0012] The stepped inner hole is a three-stage stepped hole, wherein the first stage is adapted to the stator of the frameless motor to be potted.

[0013] The stepped inner hole is surrounded by a number of threaded through holes II, which are the same number as the countersunk through holes.

[0014] The sealing cap is a two-stage stepped columnar structure, wherein the outer diameter of the smaller first-stage step is adapted to the first-stage step of the stepped through hole of the upper sealing part.

[0015] The sealing cap has a through hole II at its center, and a through groove is provided on one side of the through hole II.

[0016] The through slot is used to lead out the wire harness of the frameless motor stator to be potted.

[0017] The sealing cap has several through holes III surrounding the through hole II, the same number as the threaded through holes I.

[0018] The mandrel has a two-stage stepped columnar structure, wherein the outer diameter of the smaller first-stage step is adapted to the third-stage step of the stepped inner hole of the lower sealing part, and the outer diameter of the larger first-stage step is adapted to the second-stage step of the stepped inner hole of the lower sealing part.

[0019] The center of the first-level step with a larger diameter of the mandrel is provided with a flat-bottomed blind hole, and several through holes IV are provided on the bottom side wall of the flat-bottomed blind hole.

[0020] A threaded blind hole I is provided at the center of the first-level step with a smaller diameter mandrel.

[0021] The drive spindle is a two-stage stepped columnar structure, wherein the outer diameter of the larger first-stage step is adapted to the flat-bottomed blind hole of the spindle.

[0022] The center of the side wall of the first-stage step with a larger diameter of the driving spindle is provided with a concave annular groove.

[0023] When using the potting fixture for potting, the frameless motor stator to be potted is placed between the upper and lower sealing parts. The countersunk through-hole of the upper sealing part is fixedly connected to the threaded through-hole II of the lower sealing part by screws. The smaller diameter step of the mandrel extends into the stepped inner hole of the lower sealing part, and the through-hole I of the lower sealing part is fixedly connected to the threaded blind hole I of the mandrel by screws. The potting compound is injected into the flat-bottomed blind hole of the mandrel, pushing the larger diameter step of the mandrel into the flat-bottomed blind hole of the mandrel. By pushing the mandrel forward, the potting compound is injected into the frameless motor stator to be potted through through-hole IV. The through-hole III of the sealing cap is fixedly connected to the threaded through-hole I of the upper sealing part by screws, sealing the frameless motor stator to be potted.

[0024] Furthermore, a threaded blind hole II is provided at the center of the first-stage step with a smaller diameter of the driving spindle.

[0025] The threaded blind hole II is fixedly connected to an external pressure device by screws, and the mandrel is pushed in or pulled out by the external pressure device.

[0026] Furthermore, the sealing cap has several threaded through holes III evenly surrounding the through hole II.

[0027] The threaded through hole III serves as a set screw hole during demolding.

[0028] Furthermore, a sealing gasket is provided between the frameless motor stator to be potted and the upper sealing part.

[0029] Furthermore, a sealing gasket is provided between the frameless motor stator to be potted and the lower sealing part.

[0030] Furthermore, an O-ring seal is provided in the concave annular groove of the drive spindle.

[0031] Furthermore, the upper sealing part, lower sealing part, and sealing cover are all blued with silicone oil within the temperature range [a,b] to improve corrosion resistance and demolding effect, where a and b are both positive numbers.

[0032] Furthermore, the materials used for the mandrel include polytetrafluoroethylene and polyoxymethylene.

[0033] Furthermore, the material used for the drive spindle includes aluminum.

[0034] A method for filling using the above-mentioned filling tooling includes the following steps:

[0035] 1) Install sealing gaskets at both ends of the frameless motor stator to be potted, place the installed frameless motor stator between the upper sealing part and the lower sealing part, and fix the upper sealing part and the lower sealing part with screws.

[0036] 2) After uniformly spraying the release agent on the outer surface of the mandrel, fix the mandrel in the lower sealing part to obtain the mounting part I.

[0037] 3) After preheating the mounting part I at temperature c for time d, remove the mounting part I. Here, c and d are both positive numbers.

[0038] 4) Inject the potting compound into the flat-bottomed blind hole of the mandrel.

[0039] 5) After uniformly spraying the release agent on the outer surface of the push mandrel, install the O-ring seal in the concave annular groove, and push the push mandrel into the flat-bottomed blind hole of the mandrel, so that the potting adhesive is injected into the frameless motor stator to be potted from the through hole IV, thus obtaining the mounting part II.

[0040] 6) Allow mounting part II to stand or degas it in a vacuum environment, and observe the potting of the potting compound.

[0041] If no potting compound seeps out from the upper surface of the frameless motor stator to be potted, return to step 4.

[0042] If potting compound seeps out from the upper surface of the frameless motor stator to be potted, clean the outer surface of mounting part II and proceed to step 7).

[0043] 7) Draw out the wire harness of the frameless motor stator to be potted, install and fix the sealing cover, clean up the overflowing potting adhesive, and obtain mounting part III.

[0044] 8) After curing at temperature e for time f, remove and cool mounting part III, where e and f are both positive numbers.

[0045] 9) Disassemble the potting fixture to obtain the coarsely potted frameless motor stator.

[0046] 10) Clean the rough-filled frameless motor stator by removing the burrs and adhesive residues to obtain the finished frameless motor stator potting product.

[0047] The technical effects of this invention are undeniable. This invention provides a manual potting fixture and potting method for frameless motor stators, which improves the traditional manual potting technology for frameless motor stators and ensures potting quality, efficiency and consistency at the same time. It is mainly suitable for manual potting operations of frameless motor stators with high slot fill factor, small volume, and multiple models and small batches.

[0048] This invention employs a frameless motor stator potting fixture. The contact surface between the fixture and the stator coil is made of a non-metallic flexible material, ensuring that the stator coil is not damaged during installation and disassembly, and providing excellent assembly and demolding performance. The potting adhesive is quantitatively and rapidly injected into the lower part of the stator coil, i.e., the adhesive seeps from the bottom up onto the upper surface of the stator coil, significantly improving potting efficiency, reducing the variability of manual operation, and thus ensuring potting quality and consistency. Through actual process verification, completely injecting 1 kg of potting adhesive with a density of 1.9 g / ml into the frameless stator (with a fill rate of 72%), and then degassing by vacuum to allow the potting adhesive to penetrate into the stator coil until the liquid surface stabilizes, requires approximately 20 minutes. Compared with traditional methods, this represents a 3-fold increase in efficiency, and the potting quality meets design requirements.

[0049] This invention can overcome the problem of manual potting of frameless motor stators with high slot fill factor, and under certain conditions, it is not limited to the selection of potting material characteristics, making process control simpler and more efficient.

[0050] The frameless motor stator potting fixture provided by this invention is easy to manufacture and has a simple and practical structure. Combined with a standardized and systematic potting method, it makes the operator's thinking clearer and greatly avoids human error. Furthermore, it takes into account the quick and safe disassembly method of the modular potting fixture, which improves the reusability of the fixture, further improves the potting efficiency, and ensures the potting quality and consistency.

[0051] This invention features a novel, simple, and aesthetically pleasing structure. Through reasonable material selection and ingenious tolerance design, it simultaneously achieves functions such as flexible assembly, thermal positioning and sealing, and cold shrinkage demolding. It also boasts rapid disassembly and reusability. Furthermore, this invention is suitable for multi-variety, small-batch manual production while ensuring potting efficiency, quality, and consistency. Attached Figure Description

[0052] Figure 1 A schematic diagram of the frameless motor stator potting fixture assembly;

[0053] Figure 2 This is a schematic diagram of the upper sealing part; Figure 2 (a) is a cross-sectional view of the upper sealing part; Figure 2 (b) is a top view of the upper sealing part;

[0054] Figure 3 This is a sectional view of the lower sealing part;

[0055] Figure 4 This is a schematic diagram of the sealing cap; Figure 4 (a) is a sectional view of the sealing cap; Figure 4 (b) is a bottom view of the sealing cap;

[0056] Figure 5 This is a sectional view of the mandrel;

[0057] Figure 6 This is a schematic diagram of a sealing gasket;

[0058] Figure 7 Schematic diagram for driving the mandrel;

[0059] Figure 8 This is a schematic diagram of the stator potting process for a frameless motor.

[0060] In the figure: upper sealing part 101, stepped through hole 1011, countersunk through hole 1012, threaded through hole I 1013, lower sealing part 102, stepped inner hole 1021, through hole I 1022, threaded through hole II 1023, sealing cover 103, through hole II 1031, through groove 1032, through hole III 1033, threaded through hole III 1034, mandrel 104, flat bottom blind hole 1041, through hole IV 1042, threaded blind hole I 1043, sealing washer 105, push mandrel 106, threaded blind hole II 1061, concave annular groove 1062, O-ring 107. Detailed Implementation

[0061] The present invention will be further described below with reference to embodiments, but it should not be construed that the scope of the present invention is limited to the following embodiments. Various substitutions and modifications made based on ordinary technical knowledge and common practices in the art without departing from the above-described technical concept of the present invention should be included within the scope of protection of the present invention.

[0062] Example 1:

[0063] See Figures 1 to 8 A frameless motor stator manual potting fixture includes: an upper sealing part 101, a lower sealing part 102, a sealing cover 103, a mandrel 104, and a push mandrel 106.

[0064] The upper sealing part 101 has a columnar structure.

[0065] The upper sealing part 101 has a stepped through hole 1011 at its center, and a number of countersunk through holes 1012 and threaded through holes 11013 of the same number are evenly surrounded around the stepped through hole 1011.

[0066] The stepped through hole 1011 is a two-stage stepped hole, wherein the second-stage step is adapted to the stator of the frameless motor to be potted.

[0067] The countersunk through holes 1012 and threaded through holes 11013 are distributed at intervals.

[0068] The lower sealing part 102 is a two-stage stepped columnar structure, wherein the center of the smaller diameter first step is provided with a through hole I1022, and the center of the larger diameter first step is provided with a stepped inner hole 1021.

[0069] The through hole I1022 and the stepped inner hole 1021 are connected, and the diameter of the connecting opening is smaller than the diameter of the through hole I1022.

[0070] The stepped inner hole 1021 is a three-stage stepped hole, wherein the first stage is adapted to the stator of the frameless motor to be potted.

[0071] The stepped inner hole 1021 is surrounded by a number of threaded through holes II1023, which are the same number as the countersunk through holes 1012.

[0072] The sealing cap 103 is a two-stage stepped columnar structure, wherein the outer diameter of the smaller first-stage step is adapted to the first-stage step of the stepped through hole 1011 of the upper sealing part 101.

[0073] The sealing cover 103 has a through hole II 1031 at its center, and a through groove 1032 is provided on one side of the through hole II 1031.

[0074] The through slot 1032 is used to lead out the wire harness of the frameless motor stator to be potted.

[0075] The sealing cap 103 has several through holes III1033 surrounding the through hole II1031, the number of which is the same as the number of threaded through holes I1013.

[0076] The mandrel 104 is a two-stage stepped columnar structure, wherein the outer diameter of the smaller first-stage step is adapted to the third-stage step of the stepped inner hole 1021 of the lower sealing part 102, and the outer diameter of the larger first-stage step is adapted to the second-stage step of the stepped inner hole 1021 of the lower sealing part 102.

[0077] The mandrel 104 has a flat-bottomed blind hole 1041 at the center of the first step with a larger diameter, and several through holes IV1042 are provided on the bottom side wall of the flat-bottomed blind hole 1041.

[0078] The mandrel 104 has a threaded blind hole I1043 at the center of the first step with a smaller diameter.

[0079] The drive spindle 106 is a two-stage stepped columnar structure, wherein the outer diameter of the larger first-stage step is adapted to the flat-bottomed blind hole 1041 of the spindle 104.

[0080] The drive spindle 106 has a concave annular groove 1062 at the center of the side wall of the first-stage step with a larger diameter.

[0081] When potting using the aforementioned potting fixture, the frameless motor stator to be potted is placed between the upper sealing part 101 and the lower sealing part 102. The countersunk through hole 1012 of the upper sealing part 101 is fixedly connected to the threaded through hole II1023 of the lower sealing part 102 by screws. The smaller diameter step of the mandrel 104 extends into the stepped inner hole 1021 of the lower sealing part 102, and the through hole I1022 of the lower sealing part 102 is fixedly connected to the threaded blind hole I1043 of the mandrel 104 by screws. The potting compound is injected into the flat-bottomed blind hole 1041 of the mandrel 104, and the larger diameter step of the mandrel 106 is pushed into the flat-bottomed blind hole 1041 of the mandrel 104. By pushing the mandrel 106, the potting compound is injected into the frameless motor stator to be potted through the through hole IV1042. The through hole III1033 of the sealing cover 103 is fixedly connected to the threaded through hole I1013 of the upper sealing part 101 by screws to seal the frameless motor stator to be potted.

[0082] Example 2:

[0083] A frameless motor stator manual potting tooling, the main technical contents of which are described in Embodiment 1, further wherein the center of the first-level step with a smaller diameter of the push spindle 106 is provided with a threaded blind hole II1061.

[0084] The threaded blind hole II1061 is fixedly connected to an external pressure device by screws, and the mandrel 106 is pushed or pulled out by the external pressure device.

[0085] Example 3:

[0086] A frameless motor stator manual potting fixture, the main technical contents of which are described in any one of Embodiments 1 to 2, further wherein a plurality of threaded through holes III1034 are uniformly surrounded around the through hole II1031 of the sealing cover 103.

[0087] The threaded through hole III1034 serves as a set screw hole during demolding.

[0088] Example 4:

[0089] A frameless motor stator manual potting fixture, the main technical contents of which are described in any one of Embodiments 1 to 3, further wherein a sealing gasket 105 is provided between the frameless motor stator to be potted and the upper sealing part 101.

[0090] Example 5:

[0091] A frameless motor stator manual potting fixture, the main technical contents of which are described in any one of embodiments 1 to 4, further wherein a sealing gasket 105 is provided between the frameless motor stator to be potted and the lower sealing part 102.

[0092] Example 6:

[0093] A frameless motor stator manual potting fixture, the main technical contents of which are described in any one of embodiments 1 to 5, further wherein an O-ring 107 is provided in the concave annular groove 1062 of the push spindle 106.

[0094] Example 7:

[0095] A frameless motor stator manual potting fixture, the main technical contents of which are described in any one of embodiments 1 to 6. Furthermore, the upper sealing part 101, the lower sealing part 102, and the sealing cover 103 are all coated with silicone oil in a temperature range [a, b] to improve corrosion resistance and demolding effect, where a and b are both positive numbers.

[0096] Example 8:

[0097] A frameless motor stator manual potting fixture, the main technical contents of which are described in any one of Examples 1 to 7, further wherein the mandrel 104 is made of materials including polytetrafluoroethylene and polyoxymethylene.

[0098] Example 9:

[0099] A frameless motor stator manual potting fixture, the main technical contents of which are described in any one of Embodiments 1 to 8, further wherein the material used for the drive spindle 106 includes aluminum.

[0100] Example 10:

[0101] A method for filling using the filling tooling described in any one of Examples 1 to 9 includes the following steps:

[0102] 1) Install sealing gaskets at both ends of the frameless motor stator to be potted, place the installed frameless motor stator between the upper sealing part and the lower sealing part, and fix the upper sealing part and the lower sealing part with screws.

[0103] 2) After uniformly spraying the release agent on the outer surface of the mandrel, fix the mandrel in the lower sealing part to obtain the mounting part I.

[0104] 3) After preheating the mounting part I at temperature c for time d, remove the mounting part I. Here, c and d are both positive numbers.

[0105] 4) Inject the potting compound into the flat-bottomed blind hole of the mandrel.

[0106] 5) After uniformly spraying the release agent on the outer surface of the push mandrel, install the O-ring seal in the concave annular groove, and push the push mandrel into the flat-bottomed blind hole of the mandrel, so that the potting adhesive is injected into the frameless motor stator to be potted from the through hole IV, thus obtaining the mounting part II.

[0107] 6) Allow mounting part II to stand or degas it in a vacuum environment, and observe the potting of the potting compound.

[0108] If no potting compound seeps out from the upper surface of the frameless motor stator to be potted, return to step 4.

[0109] If potting compound seeps out from the upper surface of the frameless motor stator to be potted, clean the outer surface of mounting part II and proceed to step 7).

[0110] 7) Draw out the wire harness of the frameless motor stator to be potted, install and fix the sealing cover, clean up the overflowing potting adhesive, and obtain mounting part III.

[0111] 8) After curing at temperature e for time f, remove and cool mounting part III, where e and f are both positive numbers.

[0112] 9) Disassemble the potting fixture to obtain the coarsely potted frameless motor stator.

[0113] 10) Clean the rough-filled frameless motor stator by removing the burrs and adhesive residues to obtain the finished frameless motor stator potting product.

[0114] Example 11:

[0115] See Figures 1 to 8 A frameless motor stator manual potting fixture includes: an upper sealing part 101, a lower sealing part 102, a sealing cover 103, a mandrel 104, and a push mandrel 106.

[0116] The upper sealing part 101 has a columnar structure.

[0117] The upper sealing part 101 has a stepped through hole 1011 at its center, and six countersunk through holes 1012 and six threaded through holes 11013 are evenly surrounded around the stepped through hole 1011.

[0118] The stepped through hole 1011 is a two-stage stepped hole, wherein the second-stage step is adapted to the stator of the frameless motor to be potted.

[0119] The countersunk through holes 1012 and threaded through holes 11013 are distributed at intervals.

[0120] The lower sealing part 102 is a two-stage stepped columnar structure, wherein the center of the smaller diameter first step is provided with a through hole I1022, and the center of the larger diameter first step is provided with a stepped inner hole 1021.

[0121] The through hole I1022 and the stepped inner hole 1021 are connected, and the diameter of the connecting opening is smaller than the diameter of the through hole I1022.

[0122] The stepped inner hole 1021 is a three-stage stepped hole, wherein the first stage is adapted to the stator of the frameless motor to be potted.

[0123] The stepped inner hole 1021 is surrounded by six threaded through holes II1023.

[0124] The sealing cap 103 is a two-stage stepped columnar structure, wherein the outer diameter of the smaller first-stage step is adapted to the first-stage step of the stepped through hole 1011 of the upper sealing part 101.

[0125] The sealing cover 103 has a through hole II 1031 at its center, and a through groove 1032 is provided on one side of the through hole II 1031.

[0126] The through slot 1032 is used to lead out the wire harness of the frameless motor stator to be potted.

[0127] The sealing cap 103 has six through holes III1033 surrounding the through hole II1031.

[0128] The mandrel 104 is a two-stage stepped columnar structure, wherein the outer diameter of the smaller first-stage step is adapted to the third-stage step of the stepped inner hole 1021 of the lower sealing part 102, and the outer diameter of the larger first-stage step is adapted to the second-stage step of the stepped inner hole 1021 of the lower sealing part 102.

[0129] The mandrel 104 has a flat-bottomed blind hole 1041 at the center of the first step with a larger diameter, and several through holes IV1042 are provided on the bottom side wall of the flat-bottomed blind hole 1041.

[0130] The mandrel 104 has a threaded blind hole I1043 at the center of the first step with a smaller diameter.

[0131] The drive spindle 106 is a two-stage stepped columnar structure, wherein the outer diameter of the larger first-stage step is adapted to the flat-bottomed blind hole 1041 of the spindle 104.

[0132] The drive spindle 106 has a concave annular groove 1062 at the center of the side wall of the first-stage step with a larger diameter.

[0133] When potting using the aforementioned potting fixture, the frameless motor stator to be potted is placed between the upper sealing part 101 and the lower sealing part 102. The countersunk through hole 1012 of the upper sealing part 101 is fixedly connected to the threaded through hole II1023 of the lower sealing part 102 by screws. The smaller diameter step of the mandrel 104 extends into the stepped inner hole 1021 of the lower sealing part 102, and the through hole I1022 of the lower sealing part 102 is fixedly connected to the threaded blind hole I1043 of the mandrel 104 by screws. The potting compound is injected into the flat-bottomed blind hole 1041 of the mandrel 104, and the larger diameter step of the mandrel 106 is pushed into the flat-bottomed blind hole 1041 of the mandrel 104. By pushing the mandrel 106, the potting compound is injected into the frameless motor stator to be potted through the through hole IV1042. The through hole III1033 of the sealing cover 103 is fixedly connected to the threaded through hole I1013 of the upper sealing part 101 by screws to seal the frameless motor stator to be potted.

[0134] Example 12:

[0135] A frameless motor stator manual potting tooling, the main technical contents of which are described in Embodiment 11, further wherein the center of the first-level step with a smaller diameter of the push spindle 106 is provided with a threaded blind hole II1061.

[0136] The threaded blind hole II1061 is fixedly connected to an external pressure device by screws, and the mandrel 106 is pushed or pulled out by the external pressure device.

[0137] Example 13:

[0138] A frameless motor stator manual potting fixture, the main technical contents of which are described in any one of Embodiments 11 to 12, further wherein three threaded through holes III1034 are evenly surrounded around the through hole II1031 of the sealing cover 103.

[0139] The threaded through hole III1034 serves as a set screw hole during demolding.

[0140] Example 14:

[0141] A frameless motor stator manual potting fixture, the main technical contents of which are described in any one of embodiments 11 to 13, further wherein a sealing gasket 105 is provided between the frameless motor stator to be potted and the upper sealing part 101.

[0142] The sealing gasket 105 is made of a material with good release properties, including silicone rubber and EPDM rubber.

[0143] Example 15:

[0144] A frameless motor stator manual potting fixture, the main technical contents of which are described in any one of embodiments 11 to 14, further wherein a sealing gasket 105 is provided between the frameless motor stator to be potted and the lower sealing part 102.

[0145] The sealing gasket 105 is made of a material with good release properties, including silicone rubber and EPDM rubber.

[0146] Example 16:

[0147] A frameless motor stator manual potting fixture, the main technical contents of which are described in any one of embodiments 11 to 15, further wherein an O-ring 107 is provided in the concave annular groove 1062 of the push spindle 106.

[0148] The O-ring 107 is a common standard part that serves as a sliding seal.

[0149] Example 17:

[0150] A frameless motor stator manual potting fixture, the main technical contents of which are described in any one of embodiments 11 to 16. Furthermore, the upper sealing part 101, the lower sealing part 102, and the sealing cover 103 are all coated with silicone oil in a temperature range of [250℃, 300℃] to improve corrosion resistance and demolding effect.

[0151] Example 18:

[0152] A frameless motor stator manual potting fixture, the main technical contents of which are described in any one of Examples 11 to 17, further wherein the mandrel 104 is made of materials including polytetrafluoroethylene and polyoxymethylene.

[0153] Example 19:

[0154] A frameless motor stator manual potting fixture, the main technical contents of which are described in any one of Embodiments 11 to 18, further wherein the material used for the drive spindle 106 includes aluminum.

[0155] Example 20:

[0156] A method for filling using the filling tooling described in any one of Examples 11 to 19 includes the following steps:

[0157] 1) Install sealing gaskets at both ends of the frameless motor stator to be potted, place the installed frameless motor stator between the upper sealing part and the lower sealing part, and fix the upper sealing part and the lower sealing part with screws.

[0158] 2) After uniformly spraying the release agent on the outer surface of the mandrel, fix the mandrel in the lower sealing part to obtain the mounting part I.

[0159] The release agent includes silicone oil-based release agents, wax-based release agents, fluorine-based release agents, etc.

[0160] 3) After preheating the mounting part I at temperature c for time d, remove the mounting part I. Here, c and d are both positive numbers.

[0161] 4) Inject the potting compound into the flat-bottomed blind hole of the mandrel.

[0162] 5) After uniformly spraying the release agent on the outer surface of the push mandrel, install the O-ring seal in the concave annular groove, and push the push mandrel into the flat-bottomed blind hole of the mandrel, so that the potting adhesive is injected into the frameless motor stator to be potted from the through hole IV, thus obtaining the mounting part II.

[0163] 6) Allow mounting part II to stand or degas it in a vacuum environment, and observe the potting of the potting compound.

[0164] If no potting compound seeps out from the upper surface of the frameless motor stator to be potted, return to step 4.

[0165] If potting compound seeps out from the upper surface of the frameless motor stator to be potted, clean the outer surface of mounting part II and proceed to step 7).

[0166] 7) Draw out the wire harness of the frameless motor stator to be potted, install and fix the sealing cover, clean up the overflowing potting adhesive, and obtain mounting part III.

[0167] 8) After curing at temperature e for time f, remove and cool mounting part III, where e and f are both positive numbers.

[0168] 9) Disassemble the potting fixture to obtain the coarsely potted frameless motor stator.

[0169] 10) Clean the rough-filled frameless motor stator by removing the burrs and adhesive residues to obtain the finished frameless motor stator potting product.

[0170] Example 21:

[0171] See Figures 1 to 8 A frameless motor stator manual potting fixture and potting method, the main technical contents of which include:

[0172] A frameless stator potting fixture includes one upper sealing part, one lower sealing part, one mounting screw a, six mounting screws b, six mounting screws c, one sealing cap, one mandrel, one sealing washer a, one sealing washer b, one push mandrel, and one O-ring; it also includes the manual potting method and steps for using this frameless motor stator potting fixture.

[0173] 1. The frameless motor stator potting fixture is as follows:

[0174] 1) Upper sealing part: The whole is circular; the two ends are machined with inner circles, one inner circle is used to assemble with sealing gasket a, and the other inner circle is used to assemble with sealing cap; 6 countersunk through holes are evenly drilled at the upper end, mainly to fit and install screw c to assemble and fasten with the lower sealing part; 6 threaded through holes are evenly drilled at the upper end, mainly to fit and install screw b to assemble and fasten with sealing cap; after processing, high temperature silicone oil blueing is performed, the main function of which is to improve the corrosion resistance of tooling and the demolding effect.

[0175] 2) Lower sealing part: The cut surface is "T" shaped; the pin has three levels of inner circles from top to bottom. The first level of inner circle is used to assemble with the sealing gasket b, and the second and third levels of inner circles are used to assemble and position with the mandrel. There is one countersunk through hole at the bottom, which is mainly used to assemble and tighten the mounting screw a with the mandrel; there are 6 threaded through holes evenly distributed at the top, which are mainly used to assemble and tighten the mounting screw c with the upper sealing part; after processing, high temperature silicone oil is used for blueing, which mainly improves the corrosion resistance of the tooling and the demolding effect.

[0176] 3) Sealing cap: The cut surface is "T" shaped; it has an inner round through hole, and a through groove is cut on its side. The inner hole is used for assembly and positioning with the mandrel, and the through groove is used for wire harness lead-out; it has an outer stop for assembly and positioning with the upper sealing part; there are 6 through holes evenly distributed at the upper end, mainly for mounting screw b to assemble and tighten with the upper sealing part; there are 3 threaded through holes evenly distributed at the upper end, which serve as set screw holes and are mainly used for demolding; after processing, it is blued with high-temperature silicone oil, mainly to improve the corrosion resistance of the tooling and the demolding effect.

[0177] 4) Mandrel: The whole is cylindrical and made of bar stock with a high coefficient of thermal expansion. The inside is machined with flat-bottomed blind holes, which are mainly used to store potting material. The inner surface roughness is high and it is used to assemble with the push mandrel with O-rings installed. The O-rings play a sliding interference fit after compression. There are 4 through holes evenly drilled on the side for the potting adhesive to flow out. The lower part is machined with a raised stop and drilled with threaded blind holes. The raised stop is mainly used to assemble with the lower sealing part, and the threaded blind holes are mainly used to install screw a to fasten with the lower sealing part.

[0178] 5) Sealing gaskets a and b: Made of materials with good demolding properties, they are circular in shape and are made by turning and cutting a cylinder. The inner hole and end face of sealing gaskets a and b are mainly used for sealing and potting the upper and lower ends of the stator core. Their outer diameter is matched and positioned with the inner hole of the upper sealing part and the lower sealing part, respectively.

[0179] 6) Push mandrel: The cut surface is "⊥" shaped and is made of lightweight bar stock with a low coefficient of thermal expansion and a certain degree of hardness; the lower outer diameter is larger and its outer surface is machined with a concave annular groove for installing O-ring seals; the upper outer diameter is smaller, mainly to reduce the contact area with the inner hole of the mandrel, thereby improving the sliding efficiency of the push mandrel; a threaded blind hole is drilled in the center of the upper part, mainly for installation and connection with the demolding tool to improve demolding efficiency.

[0180] 7) Mounting screws a, b, c, and O-rings: These are common standard parts. The mounting screws are used for connection and fastening, while the O-rings are used for sliding sealing.

[0181] 2. The usage method and potting steps of this frameless motor stator potting fixture are as follows:

[0182] 1) Assemble the sealing gaskets a and b to the wire packages at both ends of the frameless stator respectively;

[0183] 2) Insert the entire stator into the inner hole of the lower sealing part; install the upper sealing part and tighten it with the mounting screws c;

[0184] 3) After evenly spraying the release agent onto the outer surface of the mandrel, insert it into the stator and position it with the inner hole of the lower sealing part, then connect and tighten it with mounting screw a;

[0185] 4) Place the components from the previous step into a heating device for preheating and heat preservation;

[0186] 5) After the heat preservation is completed, remove the component and place it flat on the workbench with the lower sealing part facing down; and inject an appropriate amount of potting compound into the mandrel.

[0187] 6) After evenly spraying the release agent onto the push mandrel, install the O-ring seal, and then install the entire mandrel with the end closest to the O-ring seal facing downwards. Slowly push the push mandrel from top to bottom by hand or with a pressure device. At this time, the potting compound inside the mandrel will be injected into the stator space due to the pressure, and the potting compound will slowly seep out from the upper end of the stator coil from bottom to top.

[0188] 7) Place the components from the previous step steadily or put them into a vacuum machine for degassing; after degassing, apply additional adhesive and clean the outer surface of the stator coil as needed; install the sealing cover and lead out the wire harness, then tighten it in place with the mounting screw b, and clean up any excess adhesive.

[0189] 8) Place the whole piece stably in the heating equipment for curing and heat preservation; after curing is complete, remove it and let it cool naturally or by air.

[0190] 9) Remove mounting screw a, and take the mandrel and push mandrel assembly upwards as a whole. If necessary, use a mold removal tool to pull it out.

[0191] 10) Remove mounting screw b and take the sealing cap upwards;

[0192] 11) Remove mounting screw c and disassemble the upper and lower sealing parts respectively;

[0193] 12) Remove the sealing gaskets a and b at both ends of the stator and clean the flash and residue on the stator potting area; at this point, the frameless stator potting product is complete.

[0194] 13) Place the removed mandrel and push mandrel assembly in a heating device for curing and heat preservation. Use a demolding tool to detach the mandrel and push mandrel. Clean off any residual adhesive from each component and store for later use. Note: O-rings are consumable parts; replace them immediately if damage or overmolding is found after use.

Claims

1. A frameless motor stator manual potting fixture, characterized in that, include: Upper sealing part (101), lower sealing part (102), sealing cover (103), spindle (104), push spindle (106); The upper sealing part (101) has a columnar structure; The upper sealing part (101) is provided with a stepped through hole (1011) at the center, and a number of countersunk through holes (1012) and threaded through holes I (1013) of the same number are evenly surrounded around the stepped through hole (1011). The stepped through hole (1011) is a two-stage stepped hole, wherein the second-stage step is adapted to the frameless motor stator to be potted; The countersunk through holes (1012) and threaded through holes I (1013) are distributed at intervals; The lower sealing part (102) is a two-stage stepped columnar structure, wherein the center of the smaller diameter first step is provided with a through hole I (1022), and the center of the larger diameter first step is provided with a stepped inner hole (1021). The through hole I (1022) and the stepped inner hole (1021) are connected, and the diameter of the connecting opening is smaller than the diameter of the through hole I (1022); The stepped inner hole (1021) is a three-stage stepped hole, wherein the first stage is adapted to the frameless motor stator to be potted; The stepped inner hole (1021) is surrounded by a number of threaded through holes II (1023) that are the same number as the countersunk through holes (1012). The sealing cap (103) is a two-stage stepped columnar structure, wherein the outer diameter of the smaller first-stage step is adapted to the first-stage step of the stepped through hole (1011) of the upper sealing part (101); The sealing cap (103) has a through hole II (1031) at its center, and a through groove (1032) is provided on one side of the through hole II (1031). The through slot (1032) is used to lead out the wire harness of the frameless motor stator to be potted; The sealing cap (103) has several through holes III (1033) surrounding the through hole II (1031), which are the same number as the number of threaded through holes I (1013). The mandrel (104) is a two-stage stepped columnar structure, wherein the outer diameter of the smaller first-stage step is adapted to the third-stage step of the stepped inner hole (1021) of the lower sealing part (102), and the outer diameter of the larger first-stage step is adapted to the second-stage step of the stepped inner hole (1021) of the lower sealing part (102). The mandrel (104) with a larger diameter is provided with a flat-bottomed blind hole (1041) at the center of the first step, and a number of through holes IV (1042) are provided on the bottom side wall of the flat-bottomed blind hole (1041). The mandrel (104) has a threaded blind hole I (1043) at the center of the first step with a smaller diameter. The drive spindle (106) is a two-stage stepped columnar structure, wherein the outer diameter of the larger first-stage step is adapted to the flat-bottomed blind hole (1041) of the spindle (104); The drive spindle (106) with a larger diameter has a concave annular groove (1062) at the center of the first-stage step sidewall. When using the potting fixture for potting, the frameless motor stator to be potted is placed between the upper sealing part (101) and the lower sealing part (102); the countersunk through hole (1012) of the upper sealing part (101) is fixedly connected to the threaded through hole II (1023) of the lower sealing part (102) by screws; the smaller diameter step of the mandrel (104) extends into the stepped inner hole (1021) of the lower sealing part (102), and the through hole I (1022) of the lower sealing part (102) is connected to the threaded blind hole I (1023) of the mandrel (104) by screws. 43) Fixed connection; inject potting compound into the flat-bottomed blind hole (1041) of the mandrel (104), push the larger diameter first step of the mandrel (106) into the flat-bottomed blind hole (1041) of the mandrel (104); by pushing the mandrel (106), inject potting compound from the through hole IV (1042) into the frameless motor stator to be potted; the through hole III (1033) of the sealing cover (103) is fixedly connected to the threaded through hole I (1013) of the upper sealing part (101) by screws to seal the frameless motor stator to be potted.

2. The frameless motor stator manual potting fixture according to claim 1, characterized in that, The drive spindle (106) has a threaded blind hole II (1061) at the center of the first step with a smaller diameter. The threaded blind hole II (1061) is fixedly connected to an external pressure device by screws, and the mandrel (106) is pushed or pulled out by the external pressure device.

3. The frameless motor stator manual potting fixture according to claim 1, characterized in that, The sealing cap (103) has several threaded through holes III (1034) evenly surrounding the through hole II (1031). The threaded through hole III (1034) serves as the set screw hole during demolding.

4. The frameless motor stator manual potting fixture according to claim 1, characterized in that, A sealing gasket (105) is provided between the stator of the frameless motor to be potted and the upper sealing part (101).

5. The frameless motor stator manual potting fixture according to claim 1, characterized in that, A sealing gasket (105) is provided between the stator of the frameless motor to be potted and the lower sealing part (102).

6. The frameless motor stator manual potting fixture according to claim 1, characterized in that, The push spindle (106) has an O-ring (107) in its concave annular groove (1062).

7. The frameless motor stator manual potting fixture according to claim 1, characterized in that, The upper sealing part (101), the lower sealing part (102), and the sealing cover (103) all improve corrosion resistance and demolding effect by turning silicone oil blue within the temperature range [a,b], where a and b are both positive numbers.

8. The frameless motor stator manual potting fixture according to claim 1, characterized in that, The materials used for the mandrel (104) include polytetrafluoroethylene and polyoxymethylene.

9. A frameless motor stator manual potting fixture according to claim 1, characterized in that, The material used for the drive spindle (106) includes aluminum.

10. A method for filling using the filling tooling described in any one of claims 1-9, characterized in that, Includes the following steps: 1) Install sealing gaskets at both ends of the frameless motor stator to be potted, place the installed frameless motor stator between the upper sealing part and the lower sealing part, and fix the upper sealing part and the lower sealing part with screws; 2) After uniformly spraying the release agent on the outer surface of the mandrel, fix the mandrel in the lower sealing part to obtain mounting part I; 3) After preheating component I at temperature c for time d, remove component I, where c and d are both positive numbers; 4) Inject the potting compound into the flat-bottomed blind hole of the mandrel; 5) After uniformly spraying the release agent on the outer surface of the push mandrel, install the O-ring seal in the concave annular groove, and push the push mandrel into the flat-bottomed blind hole of the mandrel, so that the potting adhesive is injected into the frameless motor stator to be potted from the through hole IV, thus obtaining the mounting part II; 6) Allow mounting part II to stand or degas it in a vacuum environment, and observe the potting of the potting compound; If no potting compound seeps out from the upper surface of the frameless motor stator to be potted, return to step 4). If potting compound seeps out from the upper surface of the frameless motor stator to be potted, clean the outer surface of mounting part II and proceed to step 7). 7) Draw out the wire harness of the frameless motor stator to be potted, install and fix the sealing cover, clean up the overflowing potting adhesive, and obtain mounting part III; 8) After curing at temperature e for time f, remove and cool mounting part III, where e and f are both positive numbers; 9) Disassemble the potting fixture to obtain the coarsely potted frameless motor stator; 10) Clean the rough-filled frameless motor stator by removing the burrs and adhesive residues to obtain the finished frameless motor stator potting product.

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