Method for manufacturing motor and joint motor for humanoid robot

Abstract

The application provides a manufacturing method of a motor and a joint motor for a humanoid robot, and relates to the technical field of motors. In the manufacturing method of the motor provided in the embodiment of the application, a redundant part is formed on the radial side of the core split, the circumferential splicing of each initial core split structure is realized by using the redundant part, and thus the positioning structure can be avoided on the core split. The integrity of the core split can be ensured, the formation difficulty of the positioning part can be reduced, the manufacturing difficulty of the core split can be reduced, the turns of the wire wound on each core split can be increased, the slot fill factor can be improved, and the performance of the motor can be improved.

Description

Technical Field

[0001] This application relates to the field of motor technology, and more specifically to a method for manufacturing an electric motor and a joint motor for a humanoid robot. Background Technology

[0002] With the development of the humanoid robot industry, motors, as a core component of humanoid robots, are increasingly becoming a key research and development area, especially the joint motors used in the fingers of humanoid robots. The performance of finger joint motors has a significant impact on the robot's motion accuracy, speed, and stability.

[0003] The stator and rotor are crucial components of a motor, and their slot fill factor has a significant impact on motor performance. Currently, due to space constraints, the diameter of finger joint motors is typically around 20mm. This results in small winding slots in the core, making it difficult to wind the wire using existing winding machines, leading to a low slot fill factor and hindering the improvement of motor performance. Summary of the Invention

[0004] The purpose of this application is to overcome or at least mitigate the shortcomings of the prior art and to provide a method for manufacturing an electric motor with high slot fill factor and simple manufacturing, as well as a joint motor for humanoid robots.

[0005] According to a first aspect of this application, a method for manufacturing an electric motor is provided, comprising: Multiple initial core segment structures are formed; the initial core segment structure includes core segments and a redundant part located on one radial side of the core segment, and the circumferential sides of the redundant part form a matching splicing structure. A coil is formed on each core segment of the initial core segment structure; The redundant parts of each initial iron core segment structure are spliced ​​together circumferentially to form an initial module; Remove all redundant parts from the initial module to form the stator or rotor of the motor.

[0006] In at least one embodiment, a coil is formed on each core segment of the initial core segment structure, including: Insulating components are installed at both ends of the iron core segment; a lead wire groove is formed on the side of the insulating component away from the iron core segment. The wire is wound using a lead groove as a guide.

[0007] In at least one embodiment, a plurality of initial core segment structures are formed, including: The initial core segment structure includes a first mounting portion formed in the core segment and a second mounting portion formed in the redundant portion.

[0008] In at least one embodiment, a coil is formed on each core segment of the initial core segment structure, including: An insulating component is installed on the initial core segment structure. The insulating component is fixedly connected to the initial core segment structure through a first mounting part and a second mounting part. A lead groove is formed on the side of the insulating component away from the core segment. The wire is wound using a lead groove as a guide.

[0009] In at least one embodiment, removing all redundant parts from the initial module to form the stator or rotor of the motor includes: The redundant parts and the parts of the insulating parts that come into contact with the redundant parts are removed to form the stator or rotor.

[0010] In at least one embodiment, after the redundant parts of each initial core segment structure are spliced ​​circumferentially to form an initial module, and before all redundant parts in the initial module are removed to form the stator or rotor of the motor, the method further includes: All the iron core segments are connected to form an integrated structure using welding or potting processes.

[0011] In at least one embodiment, the redundant portions of each initial core segment structure are spliced ​​together circumferentially to form an initial module, including: Each initial core segment structure is placed sequentially inside a cylindrical splicing fixture, such that the outer peripheral wall of the core segment or redundant part is in contact with the inner peripheral wall of the splicing fixture, and the inner peripheral wall of the redundant part or core segment is in contact with the outer peripheral wall of the cylindrical auxiliary fixture in the middle of the splicing fixture. During the splicing process of any two adjacent redundant parts, the splicing structure with a circumferential protrusion in one redundant part is embedded in the splicing structure with a circumferential concavity in another redundant part.

[0012] In at least one embodiment, removing all redundant parts from the initial module to form the stator or rotor of the motor includes: Remove the redundant parts, so that the inner peripheral wall of the core segments connected to the redundant parts forms the shoe-like portion of the teeth in the stator or rotor; or... Remove the redundant parts so that the outer peripheral wall of the iron core segments connected to the redundant parts forms the yoke of the stator or rotor.

[0013] In at least one embodiment, a plurality of initial core segment structures are formed, including: Silicon steel sheets are processed by stamping to form multiple initial segmented stamps; the segmented stamps include integrally formed segmented stamps and redundant stamps, with positioning parts formed on both sides of the redundant stamps in the circumferential direction. The initial segmented laminations are stacked to form the initial core segmented structure, the stacked segmented laminations form the core segments, and the stacked redundant laminations form the redundant part.

[0014] According to a second aspect of this application, a joint motor for a humanoid robot is provided, wherein at least one of the stator and rotor of the motor is manufactured based on the motor manufacturing method provided in the first aspect above, and the stator and / or rotor includes: a plurality of iron core segments arranged circumferentially, and a coil wound on each iron core segment, wherein the circumferential ends of the iron core segments are not spliced ​​together.

[0015] In the motor manufacturing method provided in this application embodiment, by forming a redundant part on the radial side of the iron core segment, the circumferential splicing of each initial iron core segment structure is realized by using the redundant part, thereby avoiding the formation of a positioning structure on the iron core segment. This not only ensures the integrity of the iron core segment, but also reduces the difficulty of forming the positioning part, which helps to reduce the manufacturing difficulty of the iron core segment.

[0016] Moreover, by first winding the wires onto each core segment and then splicing the core segments, sufficient operating space can be provided for the winding of the wires, thereby increasing the number of turns of wires wound on each core segment, which in turn can increase the slot fill factor and help improve the performance of the motor. Attached Figure Description

[0017] Figure 1 This is a flowchart of a method for manufacturing an electric motor according to the first embodiment of this application.

[0018] Figure 2 This is a schematic diagram of the structure of the initial segmented lamination formed in the motor manufacturing method provided according to the first embodiment of this application.

[0019] Figure 3 This is a schematic diagram of the initial core segment structure formed in the motor manufacturing method provided according to the first embodiment of this application.

[0020] Figure 4 Is Figure 3 The diagram shows the structure after insulating components are installed at both ends of the axial direction of the initial core segment structure.

[0021] Figure 5 Is Figure 4 The diagram shows the structure of the coil after the initial core segment structure is formed.

[0022] Figure 6 There are two Figure 5 The diagram shows the initial segmented core structure after assembly.

[0023] Figure 7 This is a schematic diagram of the structure of the initial stator module formed in the motor manufacturing method provided according to the first embodiment of this application.

[0024] Figure 8This is a schematic diagram of the stator structure formed in the motor manufacturing method provided according to the first embodiment of this application.

[0025] Figure 9 yes Figure 8 A schematic diagram of the stator from another perspective.

[0026] Figure 10 This is a schematic diagram of the structure after the insulating components are installed at both ends of the core segments in the initial core segment structure formed in the motor manufacturing method provided according to the second embodiment of this application.

[0027] Figure 11 This is a schematic diagram of the initial core segment structure formed in the motor manufacturing method provided according to the third embodiment of this application.

[0028] Figure 12 This is a schematic diagram of the structure of the insulating component formed in the manufacturing method of the motor according to the third embodiment of this application.

[0029] Figure 13 This is a schematic diagram of the insulating component installed after the initial core segment structure is formed, according to the third embodiment of the present application, in the method for manufacturing an electric motor.

[0030] Figure 14 This is a schematic diagram of the structure of the initial segmented lamination formed in the motor manufacturing method provided according to the fourth embodiment of this application.

[0031] Explanation of reference numerals in the attached figures: 10 - Initial splitting and film processing; 11-Split lamination; 11a-Yoke; 11b-Toothed part; 11c-Boot part; 11d-Groove; 12-Redundant lamination; 12a-Recessed positioning part; 12b-Protruding positioning part; 20 - Initial core segment structure; 21 - Core segment; 211 - First mounting part; 22 - Redundancy part; 221 - Splicing structure; 222 - Second mounting part; 30 - Insulator; 31 - Lead groove; 32 - First connecting post; 33 - Second connecting post; 40 - Coil; 100 - Initial stator module; 200 - Stator. Detailed Implementation

[0032] Exemplary embodiments of this application are described below with reference to the accompanying drawings. It should be understood that these specific descriptions are for teaching those skilled in the art how to implement this application only, and are not intended to exhaustively describe all possible methods of this application, nor to limit the scope of this application.

[0033] In related technologies, the slot fill factor of the stator of micro motors, represented by finger joint motors, is usually around 20%-30%.

[0034] To improve the slot fill factor of the iron core, a segmented iron core scheme is usually adopted in related technologies. However, the inventors of this application found in the research and development process that, for the stator or rotor of the finger joint motor, if a segmented iron core scheme is adopted, the radial dimensions of the yoke and shoe of the segment are usually around 1 mm. This makes it difficult to form a structure for positioning and splicing on the segment. If the above structure is not formed on the segment, it is difficult to accurately splice the segments, resulting in increased manufacturing cost and lower yield of the stator or rotor.

[0035] The manufacturing method of the motor and the joint motor for humanoid robots provided in the following embodiments of this application are intended to solve the above-mentioned technical problems in the related art.

[0036] To facilitate understanding of the motor manufacturing method and the joint motor for humanoid robots provided in the various embodiments of this application, the stator of the joint motor for humanoid robots will be used as an example in the following embodiments to describe the motor manufacturing method.

[0037] Unless otherwise specified, the terms radial, axial, and circumferential as used below refer to the radial, axial, and circumferential directions of the stator.

[0038] First Implementation Method Reference Figures 1 to 9 First, we will introduce the method for manufacturing an electric motor and the joint motor for a humanoid robot provided according to the first embodiment of this application.

[0039] like Figure 1 The diagram shows a flowchart of a method for manufacturing an electric motor according to this embodiment. This method includes the following steps S1-S4: S1, forming multiple initial core segment structures; the initial core segment structure includes core segments and a redundant part located on one radial side of the core segment, and the circumferential sides of the redundant part form a matching splicing structure.

[0040] S2, a coil is formed on each core segment of the initial core segment structure.

[0041] S3, the redundant parts of each initial iron core segment structure are spliced ​​together circumferentially to form an initial module.

[0042] S4, remove all redundant parts from the initial module to form the stator or rotor of the motor.

[0043] In the motor manufacturing method provided in this embodiment, by forming a redundant part on the radial side of the iron core segment, the circumferential splicing of each initial iron core segment structure is realized by utilizing the redundant part, thereby avoiding the formation of a positioning structure on the iron core segment. This not only ensures the integrity of the iron core segment but also reduces the difficulty of forming the positioning part, which helps to reduce the manufacturing difficulty of the iron core segment and is conducive to reducing manufacturing costs.

[0044] In the subsequent splicing process of each initial core segment structure, the splicing structure of the redundant part plays a role in positioning and connecting, which can ensure the accuracy of splicing between each core segment, thereby reducing the manufacturing difficulty of the stator.

[0045] Moreover, the process of first winding the wires on each core segment and then splicing the core segments provides sufficient operating space for winding the wires on the core segments, which helps to increase the number of turns of wires wound on each core segment, and helps to increase the slot fill factor, thereby improving the performance of the motor.

[0046] In this embodiment, the formation of multiple initial core segment structures in step S1 includes: forming multiple initial segmented laminations 10 by processing silicon steel sheets through a stamping process; each initial segmented lamination 10 includes integrally formed segmented laminations 11 and redundant laminations 12 arranged radially, with positioning portions formed on both circumferential sides of the redundant laminations 12; and stacking the initial segmented laminations 10 to form an initial core segment structure 20, wherein the stacked segmented laminations 11 form core segments 21 and the stacked redundant laminations 12 form redundant portions 22.

[0047] like Figure 2 As shown, the initial segmented lamination 10 includes an integrally formed segmented lamination 11 and a redundant lamination 12. In this embodiment, the redundant lamination 12 is located radially inside the segmented lamination 11.

[0048] It should be noted that, in order to help readers intuitively understand the structure of the initial segmented punch 10, Figure 2 The dotted line in the figure represents the boundary between the segmented lamination 11 and the redundant lamination 12. However, in actual production, there is no dotted line between the segmented lamination 11 and the redundant lamination 12 as shown in the figure.

[0049] The segmented lamination 11 includes a yoke 11a, a toothed portion 11b, and a boot portion 11c located radially inside the toothed portion 11b. Grooves 11d are formed on both circumferential sides of the segmented lamination 11. These grooves 11d serve as winding spaces for the wire. When two segmented laminations 11 are spliced ​​together circumferentially, two adjacent grooves 11d form a complete winding groove.

[0050] like Figure 2As shown, no recesses or protrusions are formed on the yoke 11a and the tooth 11b, thus ensuring the integrity of the segmented stamping 11 and reducing the processing difficulty of the segmented stamping 11.

[0051] The redundant lamination 12 has matching positioning portions formed on both circumferential sides. Specifically, as shown in the figure... Figure 2 As shown, a recessed positioning portion 12a is formed on one circumferential side of the redundant lamination 12, and a protruding positioning portion 12b is formed on the other circumferential side, so that in two adjacent redundant laminations 12, the protruding positioning portion 12b of one redundant lamination 12 can be embedded in the recessed positioning portion 12a of the other redundant lamination 12, thereby realizing the splicing of two redundant laminations 12.

[0052] In this embodiment, a positioning portion is formed on each of the two circumferential sides of the redundant lamination 12. In other embodiments, the number of positioning portions on each circumferential side of the redundant lamination 12 may also be multiple, and those skilled in the art can set them according to actual needs. In other embodiments, the positioning portions may be in other forms, such as a combination of concave and convex portions.

[0053] In this embodiment, the radial dimensions of the redundant laminations 12 are all larger than the radial dimensions of the yoke portion 11a and the boot portion 11c, which can reduce the processing difficulty of forming the positioning portion on the redundant laminations 12.

[0054] By incorporating redundant laminations 12 with positioning portions, the radial dimensions of the yoke 11a and shoe 11c are reduced, thereby facilitating further reduction in stator diameter and promoting motor miniaturization. Furthermore, the reduction in the radial dimensions of the yoke 11a and shoe 11c reduces iron losses in the motor, thus improving its performance.

[0055] like Figure 2 As shown, the radial outer peripheral wall of the segmented punch 11 and the radial inner peripheral wall of the redundant punch 12 are both arc-shaped, and their curvatures are equal, that is, the centers of the circles containing the two peripheral walls overlap. This arrangement facilitates subsequent processes, especially the splicing process.

[0056] In this embodiment, the radial dimension of the yoke 11a is larger than that of the boot 11c. This is because the stamping process has low machining accuracy. By placing the redundant lamination 12 on the radially inner side of the segmented lamination 11, the machining accuracy of the radial dimension of the boot 11c can be ensured by subsequently removing the redundant lamination 12 using a high-precision wire cutting process. Using the wire cutting process only in the stage of removing the redundant lamination 12 helps to reduce production costs.

[0057] In this embodiment, the above steps involve stacking initial segmented laminations 10 to form an initial core segmented structure 20, stacking segmented laminations 11 to form core segments 21, and stacking redundant laminations 12 to form redundant portions 22. Specifically, this includes forming multiple initial core segmented structures 20 using a stacking fixture. Each initial core segmented structure 20 includes multiple initial segmented laminations 10 stacked axially.

[0058] The stacking fixture includes a guide structure that matches the positioning portion of the redundant laminations 12. During the initial stacking of the segmented laminations 10, the guide structure provides guidance and positioning, ensuring that each initial segmented lamination 10 completely overlaps and aligns axially. This allows multiple segmented laminations 11 to be stacked to form the core segment 21 and multiple redundant laminations 12 to be stacked to form the redundant portion 22, thus forming a... Figure 3 The initial core segment structure 20 is shown. Figure 3 The dividing lines between the initial segmented laminations 10 are not shown in the figure.

[0059] In this embodiment, the formation of a coil on the core segment of each initial core segment structure in step S2 includes: installing insulating members 30 at both ends of the core segment 21 in the initial core segment structure 20, and then winding wires to form a coil 40.

[0060] Specifically, such as Figure 4 As shown, each insulating element 30 covers one axial end face of the core segment 21, and the insulating element 30 serves an insulating function. Furthermore, the circumferential side of the insulating element 30 has a certain curvature, which helps prevent damage to the enamel coating of the wires during subsequent winding, thus contributing to ensuring the yield rate of stator manufacturing. In this embodiment, the insulating element 30 does not cover the redundant portion 22.

[0061] The insulating element 30 covers only the axial end face of the core segment 21, thereby increasing the number of turns of the wire winding and contributing to improved stator performance. Of course, those skilled in the art can, according to actual needs, make the insulating element 30 also cover the circumferential side surface of the core segment 21 to improve the insulation performance between the coil and the core segment 21. In other embodiments, the insulating element 30 also covers the circumferential sidewalls of the core segment 21.

[0062] In this embodiment, step S3 above, which splices the redundant parts of each initial core segment structure along the circumferential direction to form an initial module, includes: using splicing fixtures to splice each initial core segment structure 20 wound with coil 40 along the circumferential direction to form an initial stator module 100.

[0063] In this embodiment, the initial stator module 100 is annular. Specifically, the splicing fixture is cylindrical, and a cylindrical auxiliary fixture is provided in the center of the splicing fixture. The diameter of the inner peripheral wall of the splicing fixture is equal to the outer diameter of the initial stator module formed after splicing the initial core segment structures 20, and the diameter of the auxiliary fixture is equal to the inner diameter of the initial stator module formed after splicing the initial core segment structures 20. This ensures that the outer peripheral wall of the core segment 21 fits against the inner peripheral wall of the splicing fixture, and the inner peripheral wall of the redundant part 22 fits against the outer peripheral wall of the auxiliary fixture, thereby preventing movement between the spliced ​​initial core segment structures 20.

[0064] During the splicing process of any two adjacent redundant parts 22, a splicing structure 221 that protrudes circumferentially in one redundant part 22 is embedded in a splicing structure 221 that is recessed circumferentially in another redundant part. The splicing structure 221 that protrudes circumferentially is formed by the protruding positioning parts 12b of multiple stacked redundant pieces 12, and the splicing structure 221 that is recessed circumferentially is formed by the recessed positioning parts 12a of multiple stacked redundant pieces 12.

[0065] In this embodiment, after step S3 and before step S4, the method further includes: using an integrated process to connect all the iron core segments 21 to form an integrated structure.

[0066] The integrated process includes welding and potting processes, and the potting process will be used as an example for explanation below.

[0067] Specifically, after placing the initial stator module 100 in the potting fixture, potting compound is poured into the potting fixture so that the potting compound fills the gaps between the coils and covers the axial end face of the core segment 21; the potting compound is cured so that the formed potting compound structure wraps the core segment 21 and the coil 40.

[0068] In this embodiment, each core segment 21, coil 40, and insulating component 30 are wrapped with potting compound to form an integral structure, thereby maintaining the overall structure of each core segment 21 in the redundancy removal section 22.

[0069] In this embodiment, the same potting fixture and splicing fixture can be used, which simplifies the manufacturing process and improves production efficiency.

[0070] In this embodiment, before filling the potting compound into the potting fixture, the splicing structure is shielded using a shielding fixture, ensuring that the cured potting compound structure is not connected to the splicing structure. This facilitates the subsequent removal of the redundant part 22 and prevents the potting compound structure from affecting the cutting of the redundant part 22.

[0071] In this embodiment, the step S4 above, which removes all redundant parts in the initial module to form the stator or rotor of the motor, includes: removing the redundant part 22, such that the inner peripheral wall of the iron core segment 21 connected to the redundant part 22 forms the shoe part of the tooth in the stator 200 or rotor.

[0072] In this embodiment, the redundant part 22 is removed using wire cutting, thus separating the redundant part 22 from the iron core segment 21. Since the processing accuracy of wire cutting is higher than that of laser cutting, the use of wire cutting in this embodiment ensures the processing accuracy of the radial dimension of the boot part, which is beneficial for reducing the radial dimension of the boot part. Furthermore, wire cutting has less impact on the silicon steel sheet, contributing to reduced iron loss and ensuring the performance of the motor.

[0073] Based on the same inventive concept, this embodiment also provides a joint motor for a humanoid robot, wherein at least one of the stator and rotor in the motor is formed based on the above-described manufacturing method. The stator will be used as an example for explanation below.

[0074] like Figure 8 and Figure 9 As shown, the stator 200 includes multiple core segments 21 arranged sequentially along the circumference, and each core segment 21 is wound with a coil 40. The two ends of the core segments 21 do not form a splicing structure, that is, the contact surface of any two adjacent core segments 21 is planar.

[0075] Based on the above description of the manufacturing method, it can be seen that in the stator 200 provided in this embodiment, the circumferential ends of each core segment 21 are not connected, that is, the circumferential splicing surface of any two adjacent core segments 21 is a plane, and the extension direction of the splicing surface is parallel to the radial direction of the stator 200. The beneficial effects of the stator 200 can be referred to the above description of the stator manufacturing method, and will not be repeated here.

[0076] Testing showed that the stator 200 provided in this embodiment achieves a slot fill factor of 40%-50%, which is a significant improvement compared to the slot fill factor of related articulated motor stators. Therefore, the performance of the articulated motor provided in this embodiment is significantly improved.

[0077] The joint motor provided in this embodiment is a joint motor for the hand or foot of a humanoid robot. Specifically, in the stator of the joint motor, the radial dimension of the yoke part in the iron core segment is not less than 0.5 mm and not more than 2 mm, and the radial dimension of the boot part of the toothed part in the iron core segment is not less than 0.2 mm and not more than 0.8 mm.

[0078] It should be noted that the motor manufacturing method provided in this embodiment can also be applied to other fields, such as the wind power field.

[0079] Second Implementation Method Reference Figure 10 This application describes a method for manufacturing a stator for a joint motor for a humanoid robot according to a second embodiment. The second embodiment is a variation of the first embodiment; components with the same or similar structure or function as those in the first embodiment are labeled with the same reference numerals, and specific descriptions of these components are omitted.

[0080] The main difference between this embodiment and the first embodiment is that in step S2, a coil is formed on the core segment of each initial core segment structure, including: installing an insulating member 30 with a lead groove 31 at both ends of the core segment 21 in the initial core segment structure 20, and the wire is wound around the insulating member 30 through the guide of the lead groove 31 to form a coil 40.

[0081] like Figure 10 As shown, a plurality of radially spaced lead grooves 31 are formed on the side of the insulating member 30 away from the iron core segment 21. During the winding process, the lead grooves 31 guide the wires, so that the wires are arranged in a regular manner, which can increase the number of turns of the coil 40. Moreover, after the wires are wound, the lead grooves 31 will play the role of fixing the wires, which helps to improve the stability of the coil 40.

[0082] In addition, the circumferential edge of each lead groove 31 has a certain curvature, which can prevent damage to the enamel coating of the wire.

[0083] Third Implementation Method Reference Figure 11-13 This application describes a method for manufacturing a stator for a joint motor for a humanoid robot according to a third embodiment. The third embodiment is a variation of the first and second embodiments. Components with the same or similar structure or function as those in the above embodiments are labeled with the same reference numerals, and specific descriptions of these components are omitted.

[0084] The difference between this embodiment and the above embodiment is that the initial core segment structure 20 and the insulating component 30 formed have a mutually cooperating mounting structure.

[0085] Specifically, in step S1, multiple initial core segment structures are formed, including: the formed initial core segment structure 20 includes a first mounting portion 211 formed on the core segment 21 and a second mounting portion 222 formed on the redundant portion 22.

[0086] The first mounting portion 211 is formed on the side of the core segment 21 that is radially away from the redundant portion 22, and the first mounting portion 211 extends axially, such as... Figure 11 As shown, the first mounting part 211 is groove-shaped.

[0087] The second mounting section 222 is formed in the redundant section 22, specifically, as follows: Figure 11As shown, the second mounting part 222 is a hole that passes through the redundant part 22 along the axial direction.

[0088] It should be noted that this application does not limit the specific structure of the first mounting part 211 and the second mounting part 222, as long as they can satisfy the fixing of the insulating member 30. Those skilled in the art can set the specific structure of the first mounting part 211 and the second mounting part 222 according to actual needs.

[0089] In this embodiment, step S2, forming a coil on each core segment of the initial core segment structure, includes: mounting an insulating member 30 on the initial core segment structure 20, the insulating member 30 being fixedly connected to the initial core segment structure 20 via a first mounting portion 211 and a second mounting portion 222; a lead groove 31 being formed on the side of the insulating member 30 away from the core segment 21; and winding a wire to form a coil by guiding the lead groove 31.

[0090] like Figure 12 As shown, the insulating component 30 includes a main body located on the two axial end faces of the initial iron core segment structure 20, a first connecting post 32 and a second connecting post 33 connecting the two main bodies, and a lead wire groove 31 formed on the main body.

[0091] Combination Figure 11 , Figure 12 and Figure 13 It can be seen that the first connecting post 32 is installed in the first mounting part 211, and the second connecting post 33 is installed in the second mounting part 222.

[0092] By setting the first connecting post 32 and the second connecting post 33 of the insulating component 30 to be installed with the first mounting part 211 and the second mounting part 222 respectively, the phenomenon of displacement of the insulating component 30 can be avoided, which is conducive to ensuring the smooth progress of the subsequent wire winding process.

[0093] In this embodiment, the above steps involve mounting the insulating component 30 onto the initial core segment structure 20. The insulating component 30 is fixedly connected to the initial core segment structure 20 via the first mounting portion 211 and the second mounting portion 222. This includes forming the insulating component 30 fixedly connected to the initial core segment structure 20 through an injection molding process.

[0094] Forming the insulating component 30 directly on the initial core segment structure 20 through injection molding helps improve production efficiency, ensures the integrity of the insulating component 30, enhances the structural strength of the insulating component 30, and improves the connection strength between the insulating component 30 and the initial core segment structure 20, thus ensuring the smooth progress of subsequent wire winding processes.

[0095] In this embodiment, step S4, which removes all redundant parts from the initial module to form the stator or rotor of the motor, includes: removing the redundant parts 22 and the portion of the insulating member 30 that contacts the redundant parts 22 to form the stator or rotor.

[0096] For example, the portion of the insulating part 30 that contacts the redundant part 22, along with the redundant part 22, can be removed together using a wire cutting process.

[0097] Fourth Implementation Method Reference Figure 14 This application describes a method for manufacturing a stator for a joint motor for a humanoid robot according to a fourth embodiment. The fourth embodiment is a variation of the first, second, and third embodiments. Components with the same or similar structure or function as those in the above embodiments are labeled with the same reference numerals, and specific descriptions of these components are omitted.

[0098] The main difference between this embodiment and the first embodiment is that the redundant lamination 12 in the formed initial segmented lamination 10 is located radially outside the segmented lamination 11. For example... Figure 14 The diagram shown is a structural schematic of the initial segmented lamination 10 in this embodiment. Similarly, to facilitate the reader's intuitive understanding of the structure of the initial segmented lamination 10, Figure 14 The dotted line in the figure represents the boundary between the segmented lamination 11 and the redundant lamination 12. However, in actual production, there is no dotted line between the segmented lamination 11 and the redundant lamination 12 as shown in the figure.

[0099] Based on the initial segmented lamination 10 with the above structure, in this embodiment, step S3 above involves splicing the redundant parts of each initial core segmented structure circumferentially to form an initial module, including: placing each initial core segmented structure 20 sequentially inside a cylindrical splicing fixture, such that the outer peripheral wall of the redundant part 22 fits against the inner peripheral wall of the splicing fixture, and the inner peripheral wall of the core segment 21 located radially inside the splicing structure fits against the outer peripheral wall of the cylindrical auxiliary fixture located in the middle of the splicing fixture.

[0100] Specifically, the splicing fixture is cylindrical, and a cylindrical auxiliary fixture is provided in the center of the splicing fixture. The diameter of the inner peripheral wall of the splicing fixture is equal to the outer diameter of the initial stator module formed after splicing the initial core segment structures 20, and the diameter of the auxiliary fixture is equal to the inner diameter of the initial stator module formed after splicing the initial core segment structures 20. This ensures that the outer peripheral wall of the core segment 21 fits against the inner peripheral wall of the splicing fixture, and the inner peripheral wall of the redundant part 22 fits against the outer peripheral wall of the auxiliary fixture, so as to prevent movement between the spliced ​​initial core segment structures 20.

[0101] In this embodiment, the step S4 above, which removes all redundant parts in the initial module to form the stator or rotor of the motor, includes: removing the redundant parts 22 using a wire cutting process, so that the inner peripheral wall of the iron core segment 21 connected to the redundant parts 22 forms the yoke of the tooth in the stator 200.

[0102] This application has at least one of the following advantages: (i) The motor manufacturing method provided in the embodiments of this application forms a redundant part on the radial side of the iron core segment and uses the redundant part to realize the circumferential splicing of each initial iron core segment structure. This avoids the formation of a positioning structure on the iron core segment, which can ensure the integrity of the iron core segment and reduce the difficulty of forming the positioning part. This helps to reduce the manufacturing difficulty of the iron core segment and is conducive to reducing the manufacturing cost.

[0103] (ii) In the subsequent splicing process of each initial core segment structure, the splicing structure of the redundant part plays a role in positioning and connecting, which can ensure the accuracy of splicing between each core segment, thereby reducing the manufacturing difficulty of the stator. The process of first winding the wire on each core segment and then splicing the core segments can provide sufficient operating space for the winding of the wire on the core segments, which helps to increase the number of turns of the wire wound on each core segment, thereby increasing the slot fill factor of the stator and thus improving the performance of the stator.

[0104] (iii) The process of first winding the wires on each iron core segment and then splicing the iron core segments can provide sufficient operating space for the winding of the wires on the iron core segments, which helps to increase the number of turns of the wires wound on each iron core segment, and helps to increase the slot fill factor, thereby improving the performance of the motor.

[0105] (iv) By incorporating splicing laminations with positioning portions, the radial dimensions of the yoke and shoe portion can be reduced, thereby facilitating further reduction in stator diameter and promoting motor miniaturization. Furthermore, the reduction in the radial dimensions of the yoke and shoe portion reduces iron losses in the motor, thus improving its performance.

[0106] Of course, this application is not limited to the above-described embodiments. Those skilled in the art can make various modifications to the above-described embodiments of this application under the guidance of this application, without departing from the scope of this application.

Claims

1. A method for manufacturing an electric motor, characterized in that, include: Multiple initial core segment structures are formed; the initial core segment structure includes core segments and redundant parts located on the radial side of the core segments, and the redundant parts form matching splicing structures on both sides of the circumference. The core segments include integrally formed yokes, teeth and boots, and the radial dimensions of the redundant parts are all larger than the radial dimensions of the yokes and boots. A coil is formed on each of the core segments of the initial core segment structure; The redundant parts of each of the initial iron core segment structures are spliced ​​together circumferentially to form an initial module; The stator or rotor of the motor is formed by removing all the redundant parts in the initial module.

2. The method for manufacturing an electric motor according to claim 1, characterized in that, The formation of coils on each core segment of the initial core segment structure includes: Insulating components are installed at both ends of the axial direction of the iron core segments; a lead wire groove is formed on the side of the insulating component away from the iron core segments; The wire is wound using the guide groove.

3. The method for manufacturing an electric motor according to claim 1, characterized in that, The formation of multiple initial iron core segment structures includes: The initial core segment structure includes a first mounting portion formed on the core segment and a second mounting portion formed on the redundant portion.

4. The method for manufacturing an electric motor according to claim 3, characterized in that, The formation of coils on each core segment of the initial core segment structure includes: An insulating component is installed on the initial core segment structure, and the insulating component is fixedly connected to the initial core segment structure through the first mounting part and the second mounting part; a lead wire groove is formed on the side of the insulating component away from the core segment. The wire is wound using the guide groove.

5. The method for manufacturing an electric motor according to claim 4, characterized in that, The process of removing all redundant parts from the initial module to form the stator or rotor of the motor includes: The redundant portion and the portion of the insulating member in contact with the redundant portion are removed to form the stator or the rotor.

6. The method for manufacturing an electric motor according to claim 1, characterized in that, After the redundant parts of each of the initial core segment structures are spliced ​​together circumferentially to form an initial module, and before all the redundant parts in the initial module are removed to form the stator or rotor of the motor, the method further includes: All the iron core segments are connected to form an integrated structure using welding or potting processes.

7. The method for manufacturing an electric motor according to claim 1, characterized in that, The step of splicing the redundant parts of each of the initial core segment structures circumferentially to form an initial module includes: Each of the initial core segment structures is placed sequentially inside a cylindrical splicing fixture, such that the outer peripheral wall of the core segment or the redundant part is in contact with the inner peripheral wall of the splicing fixture, and the inner peripheral wall of the redundant part or the core segment is in contact with the outer peripheral wall of the cylindrical auxiliary fixture in the middle of the splicing fixture. During the splicing process of any two adjacent redundant parts, a splicing structure with a circumferential protrusion in one redundant part is embedded in a splicing structure with a circumferential concavity in the other redundant part.

8. The method for manufacturing an electric motor according to claim 1, characterized in that, The process of removing all redundant parts from the initial module to form the stator or rotor of the motor includes: Remove the redundant portion, such that the inner peripheral wall of the core segment connected to the redundant portion forms the shoe portion of the teeth in the stator or rotor; or... Remove the redundant portion, so that the outer peripheral wall of the core segment connected to the redundant portion forms the yoke of the stator or rotor.

9. The method for manufacturing an electric motor according to claim 1, characterized in that, The formation of multiple initial iron core segment structures includes: Silicon steel sheets are processed by a stamping process to form multiple initial segmented stampings; the segmented stampings include integrally formed segmented stampings and redundant stampings, and positioning portions are formed on both sides of the circumferential direction of the redundant stampings. The initial segmented laminations are stacked to form the initial core segmented structure, the stacked segmented laminations form the core segments, and the stacked redundant laminations form the redundant portion.

10. A joint motor for a humanoid robot, characterized in that, At least one of the stator and rotor of the motor is manufactured according to the manufacturing method of the motor according to any one of claims 1-9, the stator and / or rotor comprising: a plurality of circumferentially arranged iron core segments, and a coil wound on each iron core segment, wherein the circumferential ends of the iron core segments are not spliced ​​together.

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