Winding type motor stator core and flexible manufacturing method thereof

Abstract

The embodiment of the invention discloses a winding type motor stator iron core which is formed by winding at least one layer of soft magnetic material belt for multiple times, and a plurality of patterns are manufactured at the positions where tooth grooves are formed in advance before the soft magnetic material belt is wound; and after winding, the plurality of patterns jointly form a preset three-dimensional geometric structure on the stator teeth or the stator yoke part of the winding type motor stator iron core. The embodiment of the invention further discloses a flexible manufacturing method of the winding type motor stator core. According to the winding type motor stator core, various technical effects can be realized according to different three-dimensional geometric structures, and the technical problem that the winding type motor stator core can be designed but cannot be manufactured is solved.

Description

Technical Field

[0001] This invention relates to the field of electric motors, and more particularly to a wound motor stator core and its flexible manufacturing method. Background Technology

[0002] Axial flux motors pursue extremely high power density and efficiency, and their stator design must simultaneously meet multiple objectives such as electromagnetic conversion, heat dissipation management, reliable fixation, and efficient production. Traditional manufacturing methods have fundamental limitations: 1. Bulky structure: Requirements such as winding friendliness, heat dissipation, and fixation usually need to be met by adding different components (such as insulation layers, external water-cooling jackets, and mounting flanges). This leads to complex structures, increased size, and mutual interference between various functional systems (magnetic circuits, thermal circuits, and force flow). For example, fixing bolt holes cut off the optimal magnetic circuit, and external heat sinks increase thermal resistance. 2. Process defects: Traditional stamping and stacking processes heavily rely on stamping dies, making it impossible to economically manufacture complex three-dimensional features such as internal flow channels, irregular tooth tips, and integrated fixing slots, which greatly limits the improvement of stator structures.

[0003] Existing technologies mostly address single problems. For example, patent CN106026555A discloses a method for continuously winding iron cores, but it does not solve the integration problem between the stator and external systems. Various patents concerning stator tooth fillets or cooling channels also fail to consider the stator as a system functional module and optimize fixed solutions as core design variables. A highly flexible process can integrate multiple functional features as arbitrarily combinable "design variables" to systematically resolve these contradictions.

[0004] Patent CN209104924U discloses a winding structure for an axial flux stator. However, this patent does not disclose whether the axial flux stator is made of flexible magnetic tape that has been flexibly cut and wound. If it is formed by stamping or machining, it will increase the processing difficulty. Secondly, the grooves on the tooth slots all point to the axis, resulting in low power density and efficiency of the axial flux stator. In addition, the lower end face of the axial flux stator does not have a slot for connecting other external mechanical parts, which makes installation inconvenient and prevents connection with other functional components. Summary of the Invention

[0005] This invention discloses a wound motor stator core, the purpose of which is to improve the structure of the wound motor stator core in order to overcome the defects of existing motor stator cores in the background art.

[0006] The technical features of the stator core of this wound motor are as follows: A wound motor stator core is formed by winding at least one layer of soft magnetic material strip multiple times. Before winding, a number of patterns are pre-made on the soft magnetic material strip at the position where the tooth groove is formed. After winding, the patterns together form a preset three-dimensional geometric structure on the stator teeth or stator yoke of the stator core.

[0007] In some embodiments, the three-dimensional geometry is: the vertical edges of the stator teeth are rounded.

[0008] In some embodiments, the three-dimensional geometry is: the geometry of the stator teeth is designed to be a shape formed by non-uniform variation along the axial or radial direction of the stator core of the wound motor.

[0009] In some embodiments, the three-dimensional geometry is: a flow channel for the cooling medium to circulate on the stator teeth or stator yoke.

[0010] In some embodiments, the three-dimensional geometry is: a plurality of slots provided on the stator yoke.

[0011] In some embodiments, the three-dimensional geometry is: a flow channel for cooling medium to circulate on the stator teeth or stator yoke, a slot located outside the flow channel on the stator yoke, and a cavity between the flow channel and the slot.

[0012] In some embodiments, the soft magnetic material is any one or a combination of several of amorphous alloys, silicon steel, iron-cobalt alloys, and permalloy.

[0013] The present invention also provides a flexible manufacturing method for a wound motor stator core, comprising the following steps: S1: Provide at least one layer of soft magnetic material strip; S2: A number of patterns are cut out from the soft magnetic material strip using a moldless flexible precision cutting process to obtain the unfolded stator core of the aforementioned wound motor. S3: The cut soft magnetic material strip is wound and solidified to obtain the wound motor stator core.

[0014] In some embodiments, in step S2, the moldless flexible precision cutting process includes any one of wire cutting, plasma cutting, laser cutting, or high-pressure water jet cutting.

[0015] The wound motor stator core disclosed in this invention application has the following technical advantages: Before winding at least one layer of soft magnetic material, a number of patterns are pre-fabricated at the locations where the tooth grooves are formed; after winding, these patterns collectively form a preset three-dimensional geometric structure on the stator teeth or stator yoke of the stator core. Therefore, different patterns can be pre-fabricated on the soft magnetic material strip according to different preset three-dimensional geometric structures, and different three-dimensional geometric structures can achieve different functions. This solves the problem in the prior art that only three-dimensional geometric structures can be designed for wound motor stator cores but cannot be manufactured. Simultaneously, the three-dimensional geometric structure design can be diversified, allowing the wound motor stator core structure to flexibly integrate one or more innovative features designed to solve specific engineering problems as needed. This results in a series of stator design schemes ranging from single-function improvements to overall system optimization, ensuring efficient and precise manufacturing.

[0016] These three-dimensional geometric structures and their corresponding technical effects can be, for example: The three-dimensional geometry is as follows: the vertical edges of the stator teeth are rounded. The resulting technical effect is to prevent the insulation layer of the winding from being scratched by the four edges of the stator teeth, thus protecting the insulation layer of the winding. The three-dimensional geometric structure is as follows: the geometric dimensions of the stator teeth are designed to be non-uniformly varied along the axial or radial direction of the stator core of the wound motor. The technical effects achieved are: weakening harmonic components, reducing cogging torque and torque fluctuation, reducing noise and vibration, and improving the smoothness of the stator core operation of the wound motor. The three-dimensional geometry is: a flow channel for cooling medium to circulate on the stator teeth or stator yoke, which achieves the technical effect of reducing the operating temperature; The three-dimensional geometric structure consists of several slots on the stator yoke, which facilitates the connection of the stator to the motor housing or end cover.

[0017] The three-dimensional geometric structure consists of a flow channel for cooling medium to circulate on the stator teeth or stator yoke, a slot located outside the flow channel on the stator yoke, and a cavity between the flow channel and the slot. The technical effects achieved are: the flow channel can reduce the operating temperature of the stator, the slot facilitates connection to the motor housing or end cover, and the cavity further accelerates the cooling process. The three-dimensional geometric structure is as follows: some weight-reducing grooves are set on the lower end face of the stator yoke, which achieves the technical effect of reducing the weight of the stator core of the wound motor.

[0018] The flexible manufacturing method for wound motor stator core disclosed in this invention achieves the following technical effects: it ensures that different optimized three-dimensional geometric structures of the wound motor stator core can be manufactured accurately and efficiently, thereby realizing the technical effects brought about by different three-dimensional geometric structures on the wound motor stator core, and solving the technical problem that the wound motor stator core can be designed but not manufactured. Attached Figure Description

[0019] Figure 1 A schematic diagram of the structure of a soft magnetic material strip 20 wound into a wound motor stator core 10; Figure 2 This is a schematic diagram of the structure of the stator core 10 of a wound motor; Figure 3 A schematic diagram showing the shape formed by the non-uniform variation of the stator teeth 15 of the stator core 10 of a wound motor along the axis 40 or radial line 41. Figure 4 A schematic diagram of a soft magnetic material strip for cutting and producing the stator core of a wound motor. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. The terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. Furthermore, unless otherwise explicitly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0022] refer to Figure 1 and Figure 2The wound motor stator core 10 disclosed in this invention consists of at least one layer of soft magnetic material strip 20 (although... Figure 1 and Figure 4 Only one layer is shown as an example, but multiple layers of soft magnetic material strip 20 can be wound simultaneously as needed. The soft magnetic material strip 20 is formed through multiple windings. Before winding, a number of patterns are pre-fabricated at the locations where the tooth groove 11 is formed. After winding, these patterns collectively form a pre-defined three-dimensional geometric structure on the stator teeth or stator yoke of the stator core. (Reference) Figure 2 It is understandable that if the preset three-dimensional geometric structure on the stator core 10 of the wound motor is different, the corresponding pattern pre-fabricated after the soft magnetic material strip 20 is unwound, and the position of the pattern on the soft magnetic material strip 20, will also be different. When the soft magnetic material strip 20 is wound into the stator core 10 of the wound motor, the preset three-dimensional geometric structure is formed on the stator teeth 15 or stator yoke 16 of the wound stator core 10 after the patterns at different positions on the soft magnetic material strip 20 are wound together. Therefore, different patterns can be processed at different positions when the soft magnetic material strip 20 is in the unwound state according to different three-dimensional geometric structures to meet personalized design requirements. It is understandable that different three-dimensional geometric structures will result in different optimizations and improvements in the performance of the stator core 10 of the wound motor. The following describes the technical effects brought about by the optimization of the three-dimensional geometric structure at different positions on the stator core 10 of the wound motor through several embodiments. Example

[0023] The three-dimensional geometry is as follows: the vertical edges of the stator teeth are rounded.

[0024] refer to Figure 2 The improved three-dimensional geometry of the stator core 10 of the wound motor is as follows: the four vertical edges of each stator tooth 15 of the wound motor stator core 10 are rounded 151. Because the four vertical edges of each stator tooth 15 are rounded 151, during the winding process (i.e., winding the coil roundly from bottom to top on the stator tooth 15), the insulation layer of the winding is prevented from being scratched by the original four sharp edges of the stator tooth 15, thus protecting the insulation layer of the winding. It can be understood that when the four vertical edges of each stator tooth 15 of the wound motor stator core 10 are designed with a rounded 151 three-dimensional geometry, a number of patterns are pre-made at the slot positions 21 on the soft magnetic material strip 20 before winding. It should be noted that the shape and position of the soft magnetic material strip 20 are precisely designed by the programming program, so as to ensure that after the soft magnetic material strip 20 is wound into the stator core 10 of the wound motor, the four vertical edges of each stator tooth 15 are designed as a three-dimensional geometric structure with rounded corners 151. Example

[0025] The three-dimensional geometry is as follows: the geometric dimensions of the stator teeth are designed to be the shape formed by the non-uniform variation of the axial or radial direction of the stator core of the wound motor.

[0026] refer to Figure 3 The improved three-dimensional geometry of the stator core 10 of the wound motor is as follows: the stator teeth 15 are shaped by non-uniform changes in geometric dimensions along the axis 40 or radial line 41. In other words, the longitudinal cross-section of the stator teeth 15 is shaped by non-uniform changes along the radial line 41, or the horizontal cross-section is shaped by non-uniform changes along the axis 40. The technical effects of this design are: reducing harmonic components, decreasing cogging torque and torque ripple, reducing noise and vibration, and improving the smoothness of operation of the stator core 10 of the wound motor.

[0027] It is understandable that, in order to achieve the shape formed by the non-uniform change of each stator tooth 15 in the direction along the axis 40 or radial line 41 of the wound motor stator core 10, a number of patterns are pre-fabricated at the tooth groove positions 21 on the soft magnetic material strip 20 before winding. It should be noted that the shape and position of such patterns on the soft magnetic material strip 20 are precisely designed by a programming program, thereby ensuring that after the soft magnetic material strip 20 is wound into the wound motor stator core 10, the three-dimensional geometric structure formed by the non-uniform change of each stator tooth 15 along the axis 40 or radial line 41 is achieved. It is certain that the pattern shape and position on the soft magnetic material strip 20 in this embodiment are different from those in the previous two embodiments. Example

[0028] The three-dimensional geometry consists of flow channels for the cooling medium to circulate, located on the stator teeth or stator yoke. Specifically, refer to... Figure 2 A flow channel 13 for the cooling medium is provided on the stator teeth 15 or the stator yoke 16. It should be noted that... Figure 2 In this design, the flow channel 13 is only exemplarily provided on the stator teeth 15, but it can also be provided on the stator yoke 16 as needed. The flow channel 13 can be, for example, a meandering channel, an S-shaped channel with multiple bends, or a U-shaped bend structure. The flow channel 13 can contain a cooling liquid, which can be any one or a mixture of several of the following: cold water, ethylene glycol aqueous solution, synthetic grease, chlorinated liquid, and nanofluids; or it can contain a cooling gas, which can be any one or a mixture of several of the following: air, nitrogen, hydrogen, or helium. The technical effect of adding cooling liquid or cooling gas is to reduce the operating temperature of the stator core of the wound motor and improve its service life. It should be noted that the number of flow channels 13 can be random, for example, there can be one or more, and there is no limitation here.

[0029] It is understandable that, in order to provide flow channels 13 for cooling medium circulation on the stator teeth 15 or stator yoke 16 of the wound motor stator core 10, a number of patterns (such as punches 22) are pre-fabricated at the positions 21 where the grooves 11 are formed on the soft magnetic material strip 20 before winding. It should be noted that the shape and position of these patterns on the soft magnetic material strip 20 are precisely designed by a programming program, thereby ensuring the three-dimensional geometric structure formed on the stator teeth 15 or stator yoke 16 after the soft magnetic material strip 20 is wound into the wound motor stator core 10. It is certain that the pattern shape and position on the soft magnetic material strip 20 in this embodiment are different from those in the previous embodiments. Example

[0030] The three-dimensional geometric structure consists of several slots set on the stator yoke.

[0031] refer to Figure 2 The three-dimensional geometry consists of several slots 14 provided on the stator yoke 16. These slots 14 can be used to connect to the motor housing or end cover. The number of slots 14 can be one or more, depending on the structure of the external motor housing or end cover.

[0032] It can be understood that, in order to achieve the setting of several slots 14 on the stator yoke 16 of the wound motor stator core 10, a number of patterns are pre-fabricated at the positions 21 where the toothed grooves 11 are formed on the soft magnetic material strip 20 before winding. It should be noted that the shape and position of such patterns on the soft magnetic material strip 20 are precisely designed by a programming program, thereby ensuring the three-dimensional geometric structure exhibited by the several slots 14 formed on the stator yoke 16 after the soft magnetic material strip 20 is wound into the wound motor stator core 10. It is certain that the pattern shape and position on the soft magnetic material strip 20 in this embodiment are different from those in the aforementioned embodiments. Example

[0033] refer to Figure 2 The three-dimensional geometry consists of: a flow channel 13 for cooling medium circulation on the stator teeth or stator yoke; a slot 14 located outside the flow channel on the stator yoke 16; and a cavity (not shown) between the flow channel 13 and the slot 14. In this embodiment, the three-dimensional geometry includes the structural features of embodiments 3 and 4, and also includes the added feature of the cavity. The cavity provides a new cooling circuit for the cooling medium, thereby further accelerating the cooling process and improving the service life of the stator. Because the three-dimensional geometry of this embodiment includes the flow channel 13, the slot 14, and the cavity, the pre-fabrication of a number of patterns at the location 21 where the tooth groove 11 is formed on the soft magnetic material strip 20 before winding differs from the previous embodiments. Example

[0034] refer to Figure 2 In this embodiment, in order to reduce the weight of the stator core 10 of the wound motor, some weight-reducing grooves 17 are provided on the lower end face of the stator yoke 16. The cross-sectional shape of the weight-reducing grooves 17 can be, for example, a V-shaped cross-section, a concave cross-section, or a semi-circular cross-section, and is not limited here.

[0035] Understandably, in order to form the weight-reducing groove 17 structure, a number of patterns need to be pre-fabricated at the positions 21 where the tooth groove 11 is formed on the soft magnetic material strip 20 before winding. After the soft magnetic material strip 20 is wound into a wound motor stator core 10, the pattern forms the three-dimensional geometric structure of the weight-reducing groove 17.

[0036] It should be noted that, although Figure 2 The images show all the structures in Embodiments 1 to 6. However, the improved three-dimensional geometry of the wound motor stator core 10 described in this application can be any of the structures in Embodiments 1 to 4, while Embodiments 5 to 6 are further optimized structures based on Embodiments 1 to 4. In this sense, to achieve the optimization of different functions brought about by different three-dimensional geometries of the wound motor stator core 10 (see Embodiments 1 to 6), the soft magnetic material strip 20 needs to pre-fabricate a number of corresponding patterns at the positions where the tooth grooves are formed before winding, and these patterns need to be cut into different three-dimensional geometries using a moldless flexible precision cutting process.

[0037] In addition, refer to Figure 2 The three-dimensional geometry can also be provided with opening slots 12 on the upper surface of some tooth grooves 11. This three-dimensional geometry is a common improvement and will not be described in detail here.

[0038] refer to Figure 4 In this application, the wound motor stator core is obtained by sequentially cutting at least one layer of soft magnetic material strip 20 through a moldless flexible device 30 according to a pre-set programming program, and then winding it turn by turn. The material of the soft magnetic material strip 20 is preferably any one or a combination of amorphous alloy, silicon steel, iron-cobalt alloy, and permalloy. The thickness of the soft magnetic material strip 20 is preferably 0.2 mm, which is more conducive to moldless flexible precision cutting; other thicknesses, such as 0.15 mm, are also possible. The aforementioned moldless flexible precision cutting process is preferably any one of wire cutting, plasma cutting, laser cutting, or high-pressure water jet cutting. Since the wound motor stator core is obtained by sequentially cutting the soft magnetic material strip through a moldless flexible precision device according to a pre-set programming program and then winding it turn by turn, there is no need to design complex stamping dies, thus saving costs.

[0039] This invention also discloses a method for manufacturing a wound motor stator core, comprising: S1: Provide at least one layer of soft magnetic material strip; S2: Using a moldless flexible precision cutting process, a number of patterns are cut out from the soft magnetic material strip to obtain the unfolded stator core of the flux motor mentioned above. S3: The cut soft magnetic material strip is wound and solidified to obtain the stator core of the flux motor.

[0040] For step S1, the material of the provided soft magnetic material strip is preferably any one or a combination of several of the following: amorphous alloy, silicon steel, iron-cobalt alloy, and permalloy. The thickness of the soft magnetic material strip is preferably 0.2 mm, which facilitates moldless flexible precision cutting, but other thickness values ​​are also possible, such as 0.15 mm.

[0041] For steps S2 and S3, the moldless flexible precision cutting can be any one of wire cutting, plasma cutting, laser cutting, or high-pressure water jet cutting. Other moldless flexible precision cutting methods are also possible, but will not be listed here. For example, laser cutting (hot working) and high-pressure water jet cutting (cold working) can both produce the exact same pattern after unfolding the flux motor stator from a soft magnetic material strip of the same specifications. Both processes can achieve the processing of this complex pattern, but the cut quality, heat-affected zone, and processing speed differ. This proves that the feasibility of the structure of this invention does not depend on a specific energy processing method, but rather on the process category of "digitally controlled moldless flexible precision machining." This method for manufacturing a wound motor stator core overcomes the limitation of traditional stamping dies in manufacturing complex wound motor stator cores. Therefore, as long as the three-dimensional geometry of the wound motor stator core can be designed, it can be manufactured using this method, making continuous improvement of the wound motor stator core possible and solving the technical problem of being able to design but not manufacture.

[0042] Finally, it should be noted that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A wound motor stator core, formed by winding at least one layer of soft magnetic material strip multiple times, characterized in that: Before winding, a number of patterns are pre-made at the locations where the tooth grooves are formed on the soft magnetic material strip; after winding, the patterns together form a preset three-dimensional geometric structure on the stator teeth or stator yoke of the stator core.

2. The wound motor stator core as described in claim 1, characterized in that, The three-dimensional geometry is as follows: the vertical edges of the stator teeth are rounded.

3. The wound motor stator core as described in claim 1, characterized in that, The three-dimensional geometry is such that the geometric dimensions of the stator teeth are designed to be non-uniformly varied along the axial or radial direction of the stator core of the wound motor.

4. The wound motor stator core as described in claim 1, characterized in that, The three-dimensional geometric structure is: a flow channel for the cooling medium to circulate on the stator teeth or the stator yoke.

5. The wound motor stator core as described in claim 1, characterized in that, The three-dimensional geometric structure is: a plurality of slots provided on the stator yoke.

6. The wound motor stator core as described in claim 1, characterized in that, The three-dimensional geometric structure is: a flow channel for cooling medium to circulate on the stator teeth or stator yoke, a slot located outside the flow channel on the stator yoke, and a cavity between the flow channel and the slot.

7. The wound motor stator core as described in any one of claims 1 to 6, characterized in that, The soft magnetic material is any one or a combination of several of the following: amorphous alloy, silicon steel, iron-cobalt alloy, and permalloy.

8. A flexible manufacturing method for a wound motor stator core as described in any one of claims 1 to 7, characterized in that, Includes the following steps: S1: Provide at least one layer of soft magnetic material strip; S2: Using a moldless flexible precision cutting process, a number of patterns are cut out from the soft magnetic material strip to reveal the unfolded stator core of the wound motor as described in any one of claims 1 to 7. S3: The cut soft magnetic material strip is wound and solidified to obtain the wound motor stator core.

9. The flexible manufacturing method as described in claim 8, characterized in that, In step S2, the moldless flexible precision cutting process includes any one of wire cutting, plasma cutting, laser cutting, or high-pressure water jet cutting.

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