Method for manufacturing stator core, method for manufacturing stator, and method for manufacturing electric machine

Abstract

The invention discloses a manufacturing method of a stator core, a manufacturing method of a stator and a manufacturing method of a motor, and relates to the technical field of motors. Burrs on the surface of the stator iron core are removed through a polishing process; adopting a surface treatment process of electrophoresis and / or chemical vapor deposition, and arranging an organic insulating layer on the first surface of the stator teeth of the deburred stator core; wherein the first surface is a surface covered by a winding on stator teeth when the stator teeth of the stator core are sleeved with the winding; the thickness of the organic insulating layer is smaller than or equal to 0.05 mm. According to the surface treatment process of electrophoresis and / or chemical vapor deposition, the organic insulating layer with the thickness smaller than or equal to 0.05 mm can be formed on the first surface, on the premise that the insulating performance between the stator iron core and the winding is guaranteed, occupation of the space of the winding groove is reduced, the winding with more coils can be placed, and the groove fullness rate is improved.

Description

Technical Field

[0001] This application relates to the field of motor technology, and in particular to a method for manufacturing a stator core, a method for manufacturing a stator, and a method for manufacturing a motor. Background Technology

[0002] The stator in an electric motor typically consists of a stator core and windings. The windings are fitted onto the stator teeth of the stator core. During manufacturing, to ensure insulation between the stator core and the windings, enameled wire is usually used to form the windings, thus achieving insulation within the windings themselves. However, because enameled wire is easily scratched during assembly, relying solely on it for insulation between the windings and the stator core is unreliable. Therefore, a thicker insulating frame or insulating sleeve is also installed between the stator core and the windings to further ensure insulation.

[0003] In the process of realizing this invention, the inventors discovered that in related technologies, due to the thick insulating skeleton or insulating sleeve set between the stator core and the winding, the space of the winding slot is occupied, resulting in a low slot fill factor of the stator with the stator core.

[0004] Therefore, existing technologies suffer from a low stator slot fill factor while ensuring insulation performance between the stator core and windings. Summary of the Invention

[0005] This application provides a method for manufacturing a stator core, a method for manufacturing a stator, and a method for manufacturing a motor, in order to solve the problem in the prior art of low stator slot fill factor while ensuring the insulation performance between the stator core and the winding.

[0006] In a first aspect, embodiments of this application provide a method for manufacturing a stator core, the stator core comprising a stator tooth portion and a stator yoke portion, the stator tooth portion comprising a plurality of stator teeth, the plurality of stator teeth being uniformly distributed circumferentially along the inner ring surface of the stator yoke portion; the method includes the following steps:

[0007] The burrs on the surface of the stator core are removed by polishing.

[0008] An organic insulating layer is formed on the first surface of the stator teeth of the deburred stator core using surface treatment processes such as electrophoresis and / or chemical vapor deposition.

[0009] The first surface is the surface covered by the winding on the stator teeth when the winding is fitted onto the stator teeth of the stator core; the thickness of the organic insulating layer is ≤0.05mm. Burrs on the surface of the stator core are removed by polishing; an organic insulating layer is formed on the first surface of the stator teeth of the deburred stator core using electrophoresis and / or chemical vapor deposition surface treatment processes; the first surface is the surface covered by the winding on the stator teeth when the winding is fitted onto the stator teeth of the stator core; the thickness of the organic insulating layer is ≤0.05mm. In this way, an organic insulating layer with a thickness of ≤0.05mm can be formed on the first surface by electrophoresis and / or chemical vapor deposition. This reduces the encroachment on the winding slot space while ensuring the insulation performance between the stator core and the winding, thereby allowing for the placement of more windings and improving the slot fill factor.

[0010] Furthermore, by employing electrophoresis and / or chemical vapor deposition surface treatment processes, before applying the organic insulating layer to the first surface of the stator teeth of the deburred stator core, the burrs on the stator core surface are removed through polishing, making the inner cavity of the stator core smooth. This ensures a smooth first surface. At this point, electrophoresis and / or chemical vapor deposition are used to form the organic insulating layer on the first surface, improving the coverage quality of the organic insulating layer on the first surface. Simultaneously, because burrs are removed from the entire inner cavity, scratches on the windings can be avoided during subsequent assembly of the windings and stator core.

[0011] In one possible implementation, the stator teeth have a width ≥ 0.5 mm and no shoe-like portion. Having a stator tooth width ≥ 0.5 mm and no shoe-like portion reduces the complexity of the manufacturing and assembly process.

[0012] In one possible implementation, when the polishing process is an abrasive flow process, the removal of burrs from the stator core surface using the polishing process includes:

[0013] The stator core is clamped and fixed to the abrasive flow mill, and the axial opening of the stator core faces the discharge direction of the abrasive flow mill.

[0014] Abrasive particles are injected into the inner cavity of the stator core through the axial opening of the stator core to obtain a deburred stator core.

[0015] When the polishing process is an abrasive flow process, burrs on the first surface can be removed more effectively, while ensuring that the increase in tolerance on the first surface is relatively low.

[0016] In one possible implementation, before removing burrs from the surface of the stator core using a polishing process, the method further includes:

[0017] The surface of the stator core is subjected to sandblasting or shot peening.

[0018] The insulating layer on the surface of the silicon steel sheet used to make the stator core can be removed by sandblasting or shot blasting the surface of the stator core.

[0019] In one possible implementation, after removing the burrs from the surface of the stator core using a polishing process, the method further includes:

[0020] The deburred stator core undergoes surface pretreatment, which is used to increase the adhesion of the stator core surface.

[0021] The pre-treated stator core is immersed in a passivating agent to obtain a stator core with a passivation film on its surface.

[0022] The stator core with a passivation film on its surface is washed with water.

[0023] By pre-treating the surface of the deburred stator core and immersing it in a passivating agent, the adhesion or bonding force between the organic insulating layer and the stator core can be improved when forming an organic insulating layer on the first surface of the stator core. The stator core with a passivation film on its surface can improve the corrosion resistance of the stator core, and at the same time improve the adhesion between the organic insulating layer and the stator core.

[0024] In one possible implementation, after the surface treatment process employing electrophoresis and / or chemical vapor deposition, in which an organic insulating layer is formed on the first surface of the deburred stator teeth of the stator core, the method further includes:

[0025] Set the operating temperature range of the drying oven to 150℃~200℃;

[0026] The stator core with the organic insulating layer is placed in the drying oven for drying.

[0027] By placing the stator core with the organic insulation layer in the drying oven for drying, the resin in the organic insulation layer can be cross-linked, thereby achieving curing of the organic insulation layer. The cured organic insulation layer has better corrosion resistance, and its hardness can be increased, enhancing its adhesion to the first surface of the stator core.

[0028] In addition, it can also make the organic insulating layer have good uniformity and consistency.

[0029] In one possible implementation, injecting an abrasive stream into the inner cavity of the stator core through an axial opening to obtain a deburred stator core includes:

[0030] Abrasive flow with a pressure of 1 MPa to 8 MPa is continuously injected into the inner cavity of the stator core through the axial opening of the stator core for 0.5 min to 8 min to obtain the deburred stator core.

[0031] By continuously injecting an abrasive flow with a pressure of 1 MPa to 8 MPa into the inner cavity of the stator core for 0.5 min to 8 min, a deburred stator core is obtained. This can result in a high removal rate of both macroscopic and microscopic burrs on the stator core, thereby avoiding burrs that are not covered or removed by the organic insulation layer, and preventing further scratches on the windings, which could lead to leakage in the stator with this stator core.

[0032] In one possible implementation, the abrasive flow comprises: an abrasive material and a fluid medium, wherein the Rockwell hardness of the abrasive material is in the range of 80–90 HRA.

[0033] The Rockwell hardness of the abrasive material is in the range of 80 to 90 HRA, which ensures that the surface of the stator core is sufficiently smooth.

[0034] In one possible implementation, the volume fraction of the abrasive material in the fluid medium is in the range of 0.05% to 2.0%.

[0035] The volume fraction of the abrasive material in the fluid medium is in the range of 0.05% to 2.0%. Within this volume fraction range, effective grinding of the stator core can be ensured, while avoiding uneven grinding or surface scratches caused by excessively dense abrasive particles.

[0036] In one possible implementation, the mesh size of the abrasive material per unit volume is 5 to 250.

[0037] The abrasive material per unit volume has a mesh size of 5 to 250. The amount of abrasive material is moderate, which can avoid individual abrasive grains being too large or too small. This can ensure effective grinding of the stator core and avoid uneven grinding or surface scratches caused by abrasive grains that are too large or too dense.

[0038] In one possible implementation, when using surface treatment processes of electrophoresis and chemical vapor deposition, an organic insulating layer is formed on the first surface of the stator teeth of the deburred stator core, the method comprising:

[0039] An electrophoretic insulating layer is formed on the first surface of the stator teeth of the deburred stator core through an electrophoretic surface treatment process.

[0040] A chemical vapor deposition surface treatment is used to deposit an insulating layer on the first surface of the stator teeth of the stator core, which is provided with an electrophoretic insulating layer.

[0041] The organic insulating layer includes the electrophoretic insulating layer and the deposited insulating layer, and the electrophoretic insulating layer is closer to the first surface of the stator teeth of the stator core than the deposited insulating layer.

[0042] An electrophoretic insulating layer is first deposited on the first surface by electrophoresis, and then a deposited insulating layer is deposited on the second surface by chemical vapor deposition. The electrophoretic insulating layer and the deposited insulating layer are stacked to form the organic insulating layer, which can improve the corrosion resistance and insulation of the stator core.

[0043] In one possible implementation, after applying an organic insulating layer to the first surface of the deburred stator teeth of the stator core using a surface treatment process involving electrophoresis and / or chemical vapor deposition, the method further includes:

[0044] An organic insulating layer is formed on the second surface of the deburred stator core using surface treatment processes such as electrophoresis and / or chemical vapor deposition.

[0045] The second surface is the inner ring surface of the stator yoke located in the winding groove, and two adjacent stator teeth are positioned with the stator yoke to form the winding groove.

[0046] By employing surface treatment processes such as electrophoresis and / or chemical vapor deposition, an organic insulating layer can be formed on the second surface of the deburred stator core, which can further improve the insulation performance between the stator core and the winding.

[0047] In one possible implementation, after applying an organic insulating layer to the first surface of the deburred stator teeth of the stator core using a surface treatment process involving electrophoresis and / or chemical vapor deposition, the method further includes:

[0048] An organic insulating layer is formed on the third surface of the deburred stator core using surface treatment processes such as electrophoresis and / or chemical vapor deposition.

[0049] The third surface is the surface on the stator core other than the first surface and the second surface.

[0050] By employing surface treatment processes such as electrophoresis and / or chemical vapor deposition, an organic insulating layer can be formed on the third surface of the deburred stator core, which can further improve the insulation performance between the stator core and the winding.

[0051] Secondly, embodiments of this application also provide a method for manufacturing a stator, including: the method for manufacturing any of the above-mentioned stator cores; and the method for fitting the windings onto the stator teeth of the stator core.

[0052] The stator, by including a stator core with an organic insulating layer of ≤0.05mm thickness formed on a first surface, can reduce the encroachment on the winding slot space while ensuring the insulation performance between the stator core and the winding, thereby allowing for the placement of a larger number of windings and thus improving the slot fill factor.

[0053] In one possible implementation, the winding is bonded and fixed to the stator teeth of the stator core.

[0054] By bonding and fixing the winding to the stator teeth of the stator core, the assembly stability between the winding and the stator teeth can be ensured, thereby improving the service life of the motor with the stator core.

[0055] Thirdly, embodiments of this application also provide a method for manufacturing an electric motor, including: the above-described method for manufacturing a stator, and forming the electric motor by fitting a rotor into the inner cavity of the stator core.

[0056] This motor, by including a stator core with an organic insulating layer of ≤0.05mm thickness formed on the first surface, can reduce the encroachment on the winding slot space while ensuring the insulation performance between the stator core and the windings, thereby allowing for the placement of a larger number of windings and thus improving the slot fill factor. Attached Figure Description

[0057] To more clearly illustrate the technical solutions of the embodiments of this application, 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 this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0058] Figure 1 This is a schematic flowchart of a method for manufacturing a stator core provided in an embodiment of this application. Detailed Implementation

[0059] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0060] The terms "first," "second," etc., used in the specification and claims of this application are used to distinguish similar objects and not to describe a specific order or sequence. It should be understood that such usage can be interchanged where appropriate so that embodiments of this application can be implemented in orders other than those illustrated or described herein, and the objects distinguished by "first," "second," etc., are generally of the same class and the number of objects is not limited; for example, a first object can be one or more. Furthermore, in the specification and claims, "and / or" indicates at least one of the connected objects, and the character " / " generally indicates that the preceding and following objects are in an "or" relationship.

[0061] The steps and processes provided in the embodiments of this application will be described in detail below with reference to the accompanying drawings, through specific examples and application scenarios.

[0062] Figure 1 This is a schematic flowchart of a method for manufacturing a stator core provided in an embodiment of this application.

[0063] The stator core includes a stator tooth section and a stator yoke section. The stator tooth section includes multiple stator teeth, which are evenly distributed circumferentially along the inner surface of the stator yoke section. (See also...) Figure 1 The manufacturing method of this stator core includes the following steps:

[0064] Step 101: Remove burrs from the surface of the stator core using a polishing process;

[0065] Step 102: An organic insulating layer is formed on the first surface of the stator teeth of the deburred stator core using a surface treatment process of electrophoresis and / or chemical vapor deposition.

[0066] Wherein, the first surface is the surface on which the winding covers the stator teeth when the winding is sleeved on the stator teeth of the stator core; the thickness of the organic insulation layer is ≤0.05mm.

[0067] It should be noted that the first surface is the surface covered by the winding on the stator teeth when the winding is sleeved on the stator teeth of the stator core. Alternatively, the first surface can be formed by winding the winding directly on the stator teeth of the stator core manually or with a robotic arm. No further restrictions are imposed here.

[0068] It should be noted that electrophoresis is a common surface treatment process in industry, but it is usually used to improve the corrosion resistance of workpieces, such as the electrophoretic layer on the body of a vehicle. The insulation performance of the workpiece surface after electrophoresis has never been anticipated. The stator core provided in this application has an organic insulation layer with a thickness ≤0.05mm obtained by electrophoresis and / or chemical vapor deposition. However, since the stator core provided in this application is used in a motor with a rated voltage of less than 48V, the organic insulation layer provided in this application can meet the insulation performance requirements of that motor.

[0069] It should be noted that since existing electrophoretic paints are usually used for corrosion protection, it is unknown whether the electrophoretic layer formed has an insulating effect. The inventors of this application first creatively thought of whether it is possible to use electrophoresis to obtain an organic insulating layer that meets the insulation effect required by the stator core. Then, through a large number of experiments, they discovered an electrophoretic paint that also has insulating properties.

[0070] In this embodiment, burrs on the surface of the stator core are removed by polishing; an organic insulating layer is formed on the first surface of the stator teeth of the deburred stator core using electrophoresis and / or chemical vapor deposition surface treatment processes; wherein, the first surface is the surface covered by the winding on the stator teeth when the winding is mounted on the stator teeth of the stator core; the thickness of the organic insulating layer is ≤0.05mm. Thus, an organic insulating layer with a thickness of ≤0.05mm can be formed on the first surface by electrophoresis and / or chemical vapor deposition, which reduces the encroachment on the winding slot space while ensuring the insulation performance between the stator core and the winding, thereby allowing for the placement of a larger number of windings and improving the slot fill factor.

[0071] Furthermore, by employing electrophoresis and / or chemical vapor deposition surface treatment processes, before applying the organic insulating layer to the first surface of the deburred stator teeth of the stator core, a polishing process is used to smooth the inner cavity of the stator core, thus ensuring a smooth first surface. At this point, the electrophoresis and / or chemical vapor deposition process improves the coverage quality of the organic insulating layer on the first surface. Simultaneously, because burrs are removed from the entire inner cavity, scratches on the windings from the burrs within the stator core can be avoided during subsequent assembly of the windings and stator core.

[0072] Optionally, in some embodiments, the stator teeth have a width ≥ 0.5 mm and no shoe portion. Having a stator teeth width ≥ 0.5 mm and no shoe portion reduces the complexity of the manufacturing and assembly process.

[0073] Optionally, in some embodiments, when the polishing process is an abrasive flow process, the removal of burrs from the surface of the stator core using the polishing process includes:

[0074] The stator core is clamped and fixed to the abrasive flow mill, and the axial opening of the stator core faces the discharge direction of the abrasive flow mill.

[0075] Abrasive particles are injected into the inner cavity of the stator core through the axial opening of the stator core to obtain a deburred stator core.

[0076] When the polishing process is an abrasive flow process, burrs on the first surface can be removed more effectively, while ensuring that the increase in tolerance on the first surface is relatively low.

[0077] It should be understood that the abrasive flow mill includes a discharge port, which is set to correspond to the axial opening of the stator core. Furthermore, the discharge port is sealed to the axial opening of the stator core to ensure that the abrasive flow coming out of the discharge port can maintain a certain pressure when entering the inner cavity of the stator core, thereby ensuring the deburring effect.

[0078] When the polishing process is an abrasive flow process, burrs on the first surface can be removed more effectively, while ensuring that the increase in tolerance on the first surface is relatively low.

[0079] Optionally, in some embodiments, before removing burrs from the surface of the stator core using a polishing process, the method further includes:

[0080] The surface of the stator core is subjected to sandblasting or shot peening.

[0081] It should be understood that sandblasting or shot blasting of the stator core surface can be performed manually by holding a sandblasting gun or shot blasting gun and pointing the nozzle at the surface of the stator core to spray sand or iron shot. By impacting the surface of the stator core, rust can be removed, the insulating layer that forms the surface of the stator core can be removed, and the surface roughness of the stator core can also be increased.

[0082] It should be noted that the surface of the stator core referred to here includes both the outer surface of the stator core and the surface of the inner cavity of the stator core, without further limitation.

[0083] In this embodiment of the application, by sandblasting or shot peening the surface of the stator core, the surface of the stator core can be roughened, thereby ensuring that the first surface of the stator core is roughened, and thus improving the bonding stability between the organic insulation layer and the first surface when the organic insulation layer is formed on the first surface of the stator core.

[0084] Alternatively, the stator core that has been sandblasted or shot-blasted can be cleaned and degreased, which also helps to improve the adhesion of the organic insulation layer on the first surface.

[0085] Optionally, in some embodiments, after removing the burrs from the surface of the stator core using a polishing process, the method further includes:

[0086] The deburred stator core undergoes surface pretreatment, which is used to increase the adhesion of the stator core surface.

[0087] The pre-treated stator core is immersed in a passivating agent to obtain a stator core with a passivation film on its surface.

[0088] The stator core with a passivation film on its surface is washed with water.

[0089] By pre-treating the surface of the deburred stator core and immersing it in a passivating agent, the adhesion or bonding force between the organic insulating layer and the stator core can be improved when forming the organic insulating layer on the first surface of the stator core. Furthermore, by immersing the stator core in the passivating agent, a stator core with a passivation film on its surface is obtained. This passivation film can improve the corrosion resistance of the stator core and also enhance the adhesion between the organic insulating layer and the stator core.

[0090] Optionally, the surface pretreatment can be phosphating or silicone oil, without further limitation. When the surface pretreatment is phosphating, the degreased stator core is immersed in the phosphating solution, thereby forming phosphide on the surface of the stator core. It should be understood that the phosphide on the surface of the stator core protrudes from the surface of the stator core, but typically the height of the phosphide protruding from the surface of the stator core is 1-2 μm. Therefore, it will not affect the formation of an organic insulating layer on the surface of the stator core. At the same time, the surface phosphide can improve the adhesion between the organic insulating layer and the stator core when forming an organic insulating layer on the first surface of the stator core.

[0091] Furthermore, by immersing the stator core with phosphate deposits on its surface in a passivating agent, a stator core with a passivation film on its surface is obtained. This passivation film can improve the corrosion resistance of the stator core and also improve the adhesion between the organic insulation layer and the stator core.

[0092] It should be noted that the passivating agent mentioned above can be an alkali metal compound passivating agent, a chromic acid type passivating agent, or a phosphoric acid type passivating agent.

[0093] Optionally, in some embodiments, after the surface treatment process employing electrophoresis and / or chemical vapor deposition to form an organic insulating layer on the first surface of the deburred stator teeth of the stator core, the method further includes:

[0094] Set the operating temperature range of the drying oven to 150℃~200℃;

[0095] The stator core with the organic insulating layer is placed in the drying oven for drying.

[0096] By placing the stator core with the organic insulation layer in the drying oven for drying, the resin in the organic insulation layer can be cross-linked, thereby achieving curing of the organic insulation layer. The cured organic insulation layer has better corrosion resistance, and its hardness can be increased, enhancing its adhesion to the first surface of the stator core.

[0097] In addition, it can also make the organic insulating layer have good uniformity and consistency.

[0098] Optionally, in some embodiments, ultraviolet radiation drying method can be used to dry the organic insulating layer on the first surface of the stator core, and convection drying method can also be used to dry the organic insulating layer on the first surface of the stator core; no further limitations are made here.

[0099] Optionally, in some embodiments, injecting an abrasive stream into the inner cavity of the stator core through an axial opening to obtain a deburred stator core includes:

[0100] Abrasive flow with a pressure of 1 MPa to 8 MPa is continuously injected into the inner cavity of the stator core through the axial opening of the stator core for 0.5 min to 8 min to obtain the deburred stator core.

[0101] By continuously injecting an abrasive flow with a pressure of 1 MPa to 8 MPa into the inner cavity of the stator core for 0.5 min to 8 min, a deburred stator core is obtained. This can result in a high removal rate of both macroscopic and microscopic burrs on the stator core, thereby avoiding burrs that are not covered or removed by the organic insulation layer, and preventing further scratches on the windings, which could lead to leakage in the stator with this stator core.

[0102] Optionally, in some embodiments, the abrasive flow includes: an abrasive material and a fluid medium, wherein the Rockwell hardness of the abrasive material is in the range of 80 to 90 HRA.

[0103] The Rockwell hardness of the abrasive material is in the range of 80 to 90 HRA, which ensures that the surface of the stator core is sufficiently smooth.

[0104] Optionally, in some embodiments, the volume fraction of the abrasive material in the fluid medium is in the range of 0.05% to 2.0%.

[0105] The volume fraction of the abrasive material in the fluid medium is in the range of 0.05% to 2.0%. Within this volume fraction range, effective grinding of the stator core can be ensured, while avoiding uneven grinding or surface scratches caused by excessively dense abrasive particles.

[0106] Optionally, in some embodiments, the mesh size of the abrasive material per unit volume is 5 to 250.

[0107] It should be understood that the unit volume can be cubic decimeters or cubic centimeters, and no further limitation is made here.

[0108] The abrasive material per unit volume has a mesh size of 5 to 250. The amount of abrasive material is moderate, which can avoid individual abrasive grains being too large or too small. This can ensure effective grinding of the stator core and avoid uneven grinding or surface scratches caused by abrasive grains that are too large or too dense.

[0109] For example, the abrasive flow includes: abrasive material and fluid medium, wherein the volume fraction of the abrasive material in the fluid medium is in the range of 0.05%, and the mesh size of the abrasive material per unit volume is 5.

[0110] In another example, the abrasive flow comprises: an abrasive material and a fluid medium, wherein the volume fraction of the abrasive material in the fluid medium is in the range of 2.0%, and the mesh size of the abrasive material per unit volume is 250.

[0111] In another example, the abrasive flow includes: abrasive material and a fluid medium, wherein the volume fraction of the abrasive material in the fluid medium is in the range of 2.0%, and the mesh size of the abrasive material per unit volume is 5.

[0112] In another example, the abrasive flow comprises: abrasive material and a fluid medium, wherein the volume fraction of the abrasive material in the fluid medium is in the range of 0.05%, and the mesh size of the abrasive material per unit volume is 250.

[0113] Optionally, in some embodiments, when using surface treatment processes such as electrophoresis and chemical vapor deposition, an organic insulating layer is formed on the first surface of the stator teeth of the deburred stator core, the method comprising:

[0114] An electrophoretic insulating layer is formed on the first surface of the stator teeth of the deburred stator core through an electrophoretic surface treatment process.

[0115] A chemical vapor deposition surface treatment is used to deposit an insulating layer on the first surface of the stator teeth of the stator core, which is provided with an electrophoretic insulating layer.

[0116] The organic insulating layer includes the electrophoretic insulating layer and the deposited insulating layer, and the electrophoretic insulating layer is closer to the first surface of the stator teeth of the stator core than the deposited insulating layer.

[0117] An electrophoretic insulating layer is first deposited on the first surface by electrophoresis, and then a deposited insulating layer is deposited on the first surface by chemical vapor deposition. The electrophoretic insulating layer and the deposited insulating layer are stacked to form the organic insulating layer, which can improve the corrosion resistance and insulation of the stator core.

[0118] Optionally, in some embodiments, after applying an organic insulating layer to the first surface of the deburred stator teeth of the stator core using electrophoresis and / or chemical vapor deposition surface treatment processes, the method further includes:

[0119] An organic insulating layer is formed on the second surface of the deburred stator core using surface treatment processes such as electrophoresis and / or chemical vapor deposition.

[0120] The second surface is the inner ring surface of the stator yoke located in the winding groove, and two adjacent stator teeth are positioned with the stator yoke to form the winding groove.

[0121] By employing surface treatment processes such as electrophoresis and / or chemical vapor deposition, an organic insulating layer can be formed on the second surface of the deburred stator core, which can further improve the insulation performance between the stator core and the winding.

[0122] Optionally, in some embodiments, after applying an organic insulating layer to the first surface of the deburred stator teeth of the stator core using electrophoresis and / or chemical vapor deposition surface treatment processes, the method further includes:

[0123] An organic insulating layer is formed on the third surface of the deburred stator core using surface treatment processes such as electrophoresis and / or chemical vapor deposition.

[0124] The third surface is the surface on the stator core other than the first surface and the second surface.

[0125] By employing surface treatment processes such as electrophoresis and / or chemical vapor deposition, an organic insulating layer can be formed on the third surface of the deburred stator core, which can further improve the insulation performance between the stator core and the winding, while also improving the corrosion resistance of the entire stator core, thereby extending the service life of the stator core.

[0126] Secondly, embodiments of this application also provide a method for manufacturing a stator, including: the method for manufacturing any of the above-mentioned stator cores; and the method for fitting the windings onto the stator teeth of the stator core.

[0127] The stator, by including a stator core with an organic insulating layer of ≤0.05mm thickness formed on a first surface, can reduce the encroachment on the winding slot space while ensuring the insulation performance between the stator core and the winding, thereby allowing for the placement of a larger number of windings and thus improving the slot fill factor.

[0128] Optionally, in some embodiments, the winding is bonded and fixed to the stator teeth of the stator core.

[0129] By bonding and fixing the winding to the stator teeth of the stator core, the assembly stability between the winding and the stator teeth can be ensured, thereby improving the service life of the motor with the stator core.

[0130] Thirdly, embodiments of this application also provide a method for manufacturing an electric motor, including: the above-described method for manufacturing a stator, and forming the electric motor by fitting a rotor into the inner cavity of the stator core.

[0131] This motor, by including a stator core with an organic insulating layer of ≤0.05mm thickness formed on the first surface, can reduce the encroachment on the winding slot space while ensuring the insulation performance between the stator core and the windings, thereby allowing for the placement of a larger number of windings and thus improving the slot fill factor.

[0132] The embodiments of this application have been described above with reference to the accompanying drawings. However, this application is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of this application without departing from the spirit and scope of the claims, and all of these forms are within the protection scope of this application.

Claims

1. A method for manufacturing a stator core, characterized in that, The stator core includes a stator tooth section and a stator yoke section. The stator tooth section includes a plurality of stator teeth, which are uniformly distributed circumferentially along the inner ring surface of the stator yoke section. The manufacturing method of the stator core includes: The burrs on the surface of the stator core are removed by polishing. An organic insulating layer is formed on the first surface of the stator teeth of the deburred stator core using surface treatment processes such as electrophoresis and / or chemical vapor deposition. Wherein, the first surface is the surface on which the winding covers the stator teeth when the winding is sleeved on the stator teeth of the stator core; the thickness of the organic insulation layer is ≤0.05mm.

2. The method for manufacturing a stator core according to claim 1, characterized in that, The stator teeth have a width of ≥0.5mm and no shoe portion.

3. The method for manufacturing a stator core according to claim 1, characterized in that, When the polishing process is an abrasive flow process, the removal of burrs from the surface of the stator core using the polishing process includes: The stator core is clamped and fixed to the abrasive flow mill, and the axial opening of the stator core faces the discharge direction of the abrasive flow mill. Abrasive particles are injected into the inner cavity of the stator core through the axial opening of the stator core to obtain a deburred stator core.

4. The method for manufacturing a stator core according to claim 1, characterized in that, Before using a polishing process to remove burrs from the surface of the stator core, the method further includes: The surface of the stator core is subjected to sandblasting or shot peening.

5. The method for manufacturing a stator core according to claim 1, characterized in that, After removing burrs from the surface of the stator core using a polishing process, the method further includes: The deburred stator core undergoes surface pretreatment, which is used to increase the adhesion of the stator core surface. The pre-treated stator core is immersed in a passivating agent to obtain a stator core with a passivation film on its surface. The stator core with a passivation film on its surface is washed with water.

6. The method for manufacturing a stator core according to claim 1, characterized in that, After applying an organic insulating layer to the first surface of the deburred stator teeth of the stator core using the surface treatment process employing electrophoresis and / or chemical vapor deposition, the method further includes: Set the operating temperature range of the drying oven to 150℃~200℃; The stator core with the organic insulating layer is placed in the drying oven for drying.

7. The method for manufacturing a stator core according to claim 3, characterized in that, The process of injecting abrasive particles into the inner cavity of the stator core through an axial opening to obtain a deburred stator core includes: Abrasive flow with a pressure of 1 MPa to 8 MPa is continuously injected into the inner cavity of the stator core through the axial opening of the stator core for 0.5 min to 8 min to obtain the deburred stator core.

8. The method for manufacturing a stator core according to claim 7, characterized in that, The abrasive flow includes: abrasive material and fluid medium, wherein the Rockwell hardness of the abrasive material is in the range of 80 to 90 HRA.

9. The method for manufacturing a stator core according to claim 8, characterized in that, The volume fraction of the abrasive material in the fluid medium is in the range of 0.05% to 2.0%.

10. The method for manufacturing a stator core according to claim 8, characterized in that, The mesh size of the abrasive material per unit volume of the abrasive flow is 5 to 250.

11. The method for manufacturing a stator core according to claim 1, characterized in that, In the case of surface treatment processes employing electrophoresis and chemical vapor deposition, an organic insulating layer is formed on the first surface of the stator teeth of the deburred stator core, the method comprising: An electrophoretic insulating layer is formed on the first surface of the stator teeth of the deburred stator core through an electrophoretic surface treatment process. A chemical vapor deposition surface treatment is used to deposit an insulating layer on the first surface of the stator teeth of the stator core, which is provided with an electrophoretic insulating layer. The organic insulating layer includes the electrophoretic insulating layer and the deposited insulating layer, and the electrophoretic insulating layer is closer to the first surface of the stator teeth of the stator core than the deposited insulating layer.

12. The method for manufacturing a stator core according to claim 1, characterized in that, After applying an organic insulating layer to the first surface of the stator teeth of the deburred stator core using a surface treatment process employing electrophoresis and / or chemical vapor deposition, the method further includes: An organic insulating layer is formed on the second surface of the deburred stator core using surface treatment processes such as electrophoresis and / or chemical vapor deposition. The second surface is the inner ring surface of the stator yoke located in the winding groove, and two adjacent stator teeth are positioned with the stator yoke to form the winding groove.

13. The method for manufacturing a stator core according to claim 12, characterized in that, After applying an organic insulating layer to the first surface of the stator teeth of the deburred stator core using a surface treatment process employing electrophoresis and / or chemical vapor deposition, the method further includes: An organic insulating layer is formed on the third surface of the deburred stator core using surface treatment processes such as electrophoresis and / or chemical vapor deposition. The third surface is the surface on the stator core other than the first surface and the second surface.

14. A method for manufacturing a stator, characterized in that, The method includes: a method for manufacturing a stator core as described in any one of claims 1 to 13; and fitting a winding onto the stator teeth of the stator core.

15. The method for manufacturing a stator according to claim 14, characterized in that, The winding is bonded and fixed to the stator teeth of the stator core.

16. A method for manufacturing an electric motor, characterized in that, The method includes: a stator manufacturing method as described in any one of claims 14-15, and a rotor disposed in the inner cavity of the stator core to form the motor.

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