Production process of stator assembly

Abstract

The invention discloses a production process of a stator assembly, and relates to the technical field of motors, and the production process of the stator assembly comprises the following steps: S1, providing a plurality of coil blanks, and winding each coil blank into a conductive coil according to a preset mode; s2, a stator ring assembly is provided, the stator ring assembly is provided with a plurality of tooth parts arranged at intervals in the circumferential direction, and the conductive coils are installed on the tooth parts in a one-to-one mode; s3, a stator yoke is provided, the stator yoke is annularly arranged, the stator yoke is arranged on the periphery of the stator ring assembly in a surrounding mode, and the stator yoke and the tooth part are detachably connected and fixed; s4, electrically connecting the plurality of conductive coils according to a preset mode; according to the technical scheme provided by the invention, the conductive coil can be mounted on the stator ring assembly after being wound, so that the conductive coil can be conveniently mounted on the stator ring assembly, more layers of conductive coils can be accommodated in the slot of the stator ring assembly, the slot fullness rate of the motor stator is further improved, and the performance of the motor is improved.

Description

Technical Field

[0001] This invention relates to the field of motor technology, and in particular to a manufacturing process for a stator assembly. Background Technology

[0002] The stator assembly of a motor is an important component of motors such as generators and starters. Its main function is to generate a rotating magnetic field, which causes the motor rotor to be cut by magnetic lines of force, thereby generating current and enabling the rotor to rotate. In the existing technology, there are significant restrictions on the wire size used in the stator windings of the motor stator assembly, and the winding and installation of the stator windings are quite difficult, resulting in a low slot fill factor of the stator windings and limiting the motor performance. Summary of the Invention

[0003] The main objective of this invention is to propose a manufacturing process for stator components, which aims to improve the slot fill factor of the stator windings to enhance motor performance.

[0004] To achieve the above objectives, the stator assembly manufacturing process proposed in this invention includes the following steps: S1, providing multiple coil blanks, and winding each coil blank into a conductive coil according to a preset method; S2, providing a stator ring assembly, the stator ring assembly having multiple teeth spaced apart circumferentially, and mounting the multiple conductive coils one-to-one on the multiple teeth; S3, providing a stator yoke, the stator yoke being arranged in a ring shape, surrounding the stator ring assembly, and detachably connecting and fixing the stator yoke to the teeth; S4, electrically connecting the multiple conductive coils according to a preset method, so that the multiple conductive coils are conductive in a preset manner.

[0005] In one embodiment, in step S1, the coil blank is a flat wire, and the conductive coil is a flat wire coil.

[0006] In one embodiment, the stator ring assembly includes a stator ring and an insulating member. The stator ring includes a stator body arranged in a ring shape and a plurality of teeth spaced circumferentially on the outer wall of the stator body. The insulating member includes an insulating body arranged in a ring shape and a plurality of clearance openings spaced circumferentially on each of the clearance openings. Each clearance opening has an insulating protrusion on both sides along the axial direction of the stator ring. Step S2 includes the following steps: S21, assembling the insulating member and the stator ring such that the insulating body of the insulating member surrounds the outer circumferential surface of the stator body, and the teeth of the stator ring pass through the clearance openings of the insulating body and are located between two opposing insulating protrusions; S22, mounting a plurality of conductive coils one-to-one on the plurality of teeth and covering the insulating protrusions on both sides of the teeth.

[0007] In one embodiment, the insulating element includes a first insulating element and a second insulating element disposed opposite to each other along the axial direction of the stator ring;

[0008] Step S21 includes the following steps: S211, assembling the first insulating member along the first end of the stator ring; S212, assembling the second insulating member along the second end of the stator ring so that the second insulating member is connected to the first insulating member and forms a clearance opening for the teeth to pass through.

[0009] In one embodiment, a guide groove is provided between any two adjacent teeth. The guide groove is located on the outer side of the stator body and extends axially along the stator body. A first insert is provided on the inner side of the first insulating member, and a second insert is provided on the inner side of the second insulating member. In step S211, the first insert is inserted into the guide groove from one end along the axial direction of the stator ring to assemble the first insulating member onto the stator. In step S212, the second insert is inserted into the guide groove from the other end along the axial direction of the stator ring to assemble the second insulating member onto the stator ring.

[0010] In one embodiment, the stator ring is configured as a single-piece molded part.

[0011] In one embodiment, the stator ring assembly further includes a limiting block, and the limiting block is provided on the side of each tooth away from the stator body. The inner peripheral wall of the stator yoke is provided with a limiting groove that cooperates with the limiting block. In step S3, the limiting block is inserted into the limiting groove along the axial direction of the stator yoke so that the stator yoke is assembled to the stator ring assembly.

[0012] In one embodiment, step S4 includes the following steps: S41, providing a wire connector and connecting and fixing the wire connector to the stator ring assembly and / or the stator yoke; S42, electrically connecting the wire connector to a portion of the conductive coil.

[0013] In one embodiment, in step S42, the wire connector is connected to the conductive coil by welding.

[0014] In one embodiment, the stator yoke is configured as a single-piece molded part.

[0015] The technical solution of this invention employs the following steps in the manufacturing process of the stator assembly: providing multiple coil blanks, and winding each coil blank into a conductive coil according to a preset method; providing a stator ring assembly, the stator ring assembly having multiple teeth spaced apart circumferentially, and mounting multiple conductive coils one-to-one on the multiple teeth; subsequently providing a stator yoke, the stator yoke being ring-shaped, surrounding the stator ring assembly, and detachably connecting and fixing the stator yoke to the teeth; finally, electrically connecting the multiple conductive coils according to a preset method, so that the multiple conductive coils are conductive in a preset manner; this allows the conductive coils to be installed on the stator ring assembly after a certain number of turns have been wound, thereby facilitating the installation of more layers of conductive coils on the stator ring assembly, and allowing the slots of the stator ring assembly to accommodate more layers of conductive coils, thereby improving the slot fill factor of the motor stator and improving the performance of the motor. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0017] Figure 1 A schematic flowchart illustrating an embodiment of the manufacturing process of the stator assembly provided by the present invention; Figure 2 A schematic flowchart of step S2 in one embodiment of the stator assembly manufacturing process provided by the present invention; Figure 3 A schematic flowchart of step S21 in one embodiment of the stator assembly manufacturing process provided by the present invention; Figure 4 A schematic flowchart of step S4 in one embodiment of the stator assembly manufacturing process provided by the present invention; Figure 5 This is a schematic diagram of a stator assembly according to an embodiment of the present invention; Figure 6 This is an exploded structural diagram of an embodiment of the stator assembly provided by the present invention; Figure 7 An exploded structural diagram of the first insulating member and the second insulating member in one embodiment of the stator assembly provided by the present invention; Figure 8 A schematic diagram of the structure of the conductive coil obtained in step S1 of an embodiment of the stator assembly manufacturing process provided by the present invention. Figure 9A schematic diagram of the assembly structure of the conductive coil and the stator ring assembly in step S2 of one embodiment of the stator assembly manufacturing process provided by the present invention. Figure 10 A schematic diagram of the structure of the stator yoke and stator ring assembly after assembly in step S3 of one embodiment of the stator assembly manufacturing process provided by the present invention; Figure 11 This is a schematic diagram of the structure of the conductor connector after assembly in step S4 of one embodiment of the stator assembly manufacturing process provided by the present invention.

[0018] Explanation of icon numbers: 100. Stator assembly; 1. Conductive coil; 2. Stator ring assembly; 21. Stator ring; 211. Tooth; 212. Stator body; 213. Guide groove; 214. Limiting block; 22. Insulating component; 221. Insulating body; 222. Clearance opening; 223. Insulating protrusion; 224. First insulating component; 2241. First insert; 225. Second insulating component; 2251. Second insert; 3. Stator yoke; 31. Limiting groove; 4. Wire connector.

[0019] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. 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 a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0021] It should be noted that if the embodiments of the present invention involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indicators will also change accordingly.

[0022] Furthermore, if the embodiments of this invention involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the use of "and / or" or "and / or" throughout the text includes three parallel solutions. For example, "A and / or B" includes solution A, solution B, or a solution where both A and B are satisfied simultaneously. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0023] This invention proposes a manufacturing process for stator components.

[0024] Please see Figures 1 to 11 In one embodiment of the present invention, the manufacturing process of the stator assembly includes the following steps: S1, providing a plurality of coil blanks, and winding each coil blank into a conductive coil in a preset manner; S2, providing a stator ring assembly, the stator ring assembly having a plurality of teeth spaced apart circumferentially, and mounting the plurality of conductive coils one-to-one on the plurality of teeth; S3, providing a stator yoke, the stator yoke being arranged in a ring shape, surrounding the stator ring assembly, and detachably connecting and fixing the stator yoke to the teeth; S4, electrically connecting the plurality of conductive coils in a preset manner, so that the plurality of conductive coils are connected in a preset manner.

[0025] In this embodiment, when producing the stator assembly 100, multiple coil blanks of preset specifications are first provided. Each coil blank is wound into a conductive coil 1 using a winding device according to a preset number of turns, size, and shape. If necessary, the conductive coil 1 can be shaped and its insulation tested for subsequent assembly. Then, a stator ring assembly 2 with multiple teeth 211 spaced circumferentially is provided. The conductive coils 1 are fitted one-to-one onto the corresponding teeth 211 using automated equipment or manually, ensuring a tight fit between the conductive coils 1 and the teeth 211 and that the insulation material is intact, thus forming the winding portion of the stator assembly 100. Next, a ring-shaped stator yoke 3 is provided. The stator yoke 3 is fitted around the stator ring assembly 2 with the coils already installed and secured to the corresponding parts of the teeth 211 using bolts, clips, or other detachable connection methods. Finally, based on the phase sequence, number of poles, and connection method of the motor design, the ends of each conductive coil 1 are welded, crimped, or plugged in according to a preset rule sequence using wires, terminal blocks, or dedicated connectors to complete the electrical connection, so that the stator windings form a preset conduction relationship, ensuring that the electrical performance of the motor meets the preset requirements.

[0026] In this embodiment, the following step is also included between steps S2 and S3: S5, after installing multiple conductive coils 1 onto the stator ring 21, the coils are connected to the stator ring 21 by applying adhesive, or the stator ring 21 with the coils installed is fixed by impregnation with varnish. To limit and fix the conductive coils 1 for subsequent welding and wiring, fixing the coils to the stator ring 21 by applying adhesive or impregnation prevents the conductive coils 1 from falling off. This facilitates both the subsequent installation of the stator yoke 3 and the welding connection between the individual conductive coils 1, enabling the conductive coils 1 to form a stator winding that meets the preset requirements. Simultaneously, the following step may also be included between steps S2 and S3: S6, after the conductive coils 1 are installed, a temperature sensing element is installed on the conductive coils 1. To monitor the temperature of the conductive coil 1 during operation, a temperature sensing element is installed in the stator assembly 100. This element can be a miniaturized thermocouple, thermistor, or temperature sensor—a highly sensitive, fast-response temperature sensing component. The element is bonded to the highest temperature rise point or hot spot area within the slot of the fixed conductive coil 1 using a high-temperature resistant and thermally conductive adhesive. The installation process must ensure close contact between the sensing element and the coil conductor or insulation layer to obtain an accurate temperature signal. Simultaneously, it must ensure sufficient and reliable electrical insulation strength between the sensing element and its leads and the high-voltage coil to prevent short circuits or signal interference, thereby improving the stability of the entire motor under complex operating conditions and extending the motor's service life.

[0027] The technical solution of this invention employs the following steps in the manufacturing process of the stator assembly: providing multiple coil blanks, and winding each coil blank into a conductive coil according to a preset method; providing a stator ring assembly, the stator ring assembly having multiple teeth spaced circumferentially, and mounting multiple conductive coils one-to-one on the multiple teeth; subsequently providing a stator yoke, the stator yoke being ring-shaped, surrounding the stator ring assembly, and detachably connecting and fixing the stator yoke to the teeth; finally, electrically connecting the multiple conductive coils according to a preset method, so that the multiple conductive coils are conductive in a preset manner; this allows the conductive coils to be installed on the stator ring assembly after a certain number of turns have been wound, thereby facilitating the installation of more layers of conductive coils 1 on the stator ring assembly 2, and enabling the slots of the stator ring assembly 2 to accommodate more layers of conductive coils 1, thereby improving the slot fill factor of the motor stator and improving the performance of the motor.

[0028] See Figure 6 , Figure 8In one embodiment, in step S1, the coil blank is a flat wire, and the conductive coil 1 is a flat wire coil. In step S1, the provided coil blank is a flat wire material with a rectangular cross-section, and the surface is covered with multiple layers of high-temperature resistant insulating coating; the coil blank is formed into a flat wire coil with a preset geometric shape through a preset winding process. The flat wire coil can improve the space utilization of the stator winding, and its flat cross-sectional shape allows the wires to be arranged more closely, thereby effectively improving the fill factor of the 100 slots of the stator assembly. In other embodiments, ordinary copper wire material with a circular cross-section can also be provided, and wound into a circular wire coil with a preset shape, size, and number of turns by a winding device. Then, the circular wire coil is placed in a preset processing device, and a certain pressure is applied to the circular wire coil along the axial direction of the circular wire coil. The ductility of the coil material is used to press the circular wire coil into a flat wire coil.

[0029] See Figure 1 , Figure 2 , Figure 5 , Figure 6 In one embodiment, the stator ring assembly 2 includes a stator ring 21 and an insulating member 22. The stator ring 21 includes a stator body 212 arranged in a ring shape and a plurality of teeth 211 spaced circumferentially on the outer wall of the stator body 212. The insulating member 22 includes an insulating body 221 arranged in a ring shape. The insulating body 221 is provided with a plurality of clearance openings 222 spaced circumferentially. Each clearance opening 222 is provided with insulating protrusions 223 on both sides along the axial direction of the stator ring 21. Step S2 includes the following steps: assembling the insulating member with the stator ring so that the insulating body of the insulating member surrounds the outer circumferential surface of the stator body, and the teeth of the stator ring pass through the clearance openings of the insulating body and are located between two opposing insulating protrusions; installing a plurality of conductive coils one-to-one on the plurality of teeth and covering the insulating protrusions on both sides of the teeth.

[0030] In this embodiment, the insulating body 221 is arranged in a continuous closed ring shape and can be integrally molded onto the outside of the stator ring 21 using engineering plastic through injection molding equipment. The inner ring size of the insulating body 221 matches the outer peripheral surface of the stator body 212, allowing it to surround and wrap around the outer peripheral surface of the stator body 212. The insulating body 221 has a plurality of clearance openings 222 evenly spaced along its circumference. The number, circumferential position, and geometric contour of the clearance openings 222 are all corresponding to the plurality of protruding teeth 211 on the outer wall of the stator ring 21, and their size is equal to or slightly larger than the cross-section of the teeth 211, to ensure that the plurality of teeth 211 can be inserted one-to-one into the corresponding clearance openings 222 during assembly. This allows the insulating body 221 to completely cover the outer surface of the stator body 212 while avoiding the teeth 211 used for mounting the coil, and the teeth 211 used for winding can extend out from the clearance openings 222. The insulating protrusion 223 is configured as an insulating structure that protrudes radially outward from the outer surface of the insulating body 221. The insulating protrusion 223 is correspondingly provided at each clearance opening 222, and an insulating protrusion 223 is provided on each of the opposite sides of the clearance opening 222 along the axial direction. When the insulating body 221 is installed in place and the teeth 211 pass through the clearance opening 222, each metal tooth 211 can be located axially between the two oppositely provided insulating protrusions 223 corresponding to its clearance opening 222. Since the teeth 211 of the stator ring 21 have sharp edges, and these sharp edges are difficult to be processed into chamfers, these sharp edges are prone to friction with the conductive coil 1, and the insulation layer of the coil is easily damaged by the sharp edges of the teeth 211, leading to motor failure. The insulating protrusion 223 is used to shield or protect the parts of the teeth 211 that are prone to contact with the coil end wires, effectively preventing electrical short circuits between the coil and the metal teeth 211 due to displacement, vibration or varnish damage during winding, assembly or operation.

[0031] In step S2, the insulating component 22 is first molded onto the stator ring 21 using injection molding equipment, and the insulating body 221 of the insulating component 22 is fitted onto the outer circumferential surface of the stator body 212. Simultaneously, each tooth 211 passes through the corresponding clearance opening 222 and is positioned between the insulating protrusions 223 on both sides, thus completing the assembly of the insulating component 22 and the stator ring 21. Subsequently, multiple prepared conductive coils 1 are fitted one-to-one onto each tooth 211, ensuring that the insulating protrusions 223 on both sides of the tooth 211 are also fitted inside the conductive coil 1 to protect the insulation layer of the conductive coil 1.

[0032] See Figures 1 to 3 , Figures 5 to 7In one embodiment, the insulating member 22 includes a first insulating member 224 and a second insulating member 225 disposed opposite to each other along the axial direction of the stator ring 21; step S21 includes the following steps: assembling the first insulating member along the first end of the stator ring; assembling the second insulating member along the second end of the stator ring so that the second insulating member is mated with the first insulating member and forms a clearance opening for the tooth to pass through.

[0033] In this embodiment, the insulating member 22 adopts a split structure. The insulating member 22 includes a first insulating member 224 and a second insulating member 225 arranged opposite each other along the axial direction. In step S21, the first insulating member 224 is first moved along the axial direction and fitted onto the stator ring 21, so that its inner edge fits against the outer peripheral surface of the end of the stator ring 21 body. A limiting step can be provided on the inner peripheral surface of the insulating member 22. By abutting the limiting step against the end face of the stator ring 21 body, the first insulating member 224 is equipped on the stator ring 21 body. Then, the second insulating member 225 is moved along the axial direction from the second end of the stator ring 21 opposite to the first end and assembled onto the stator ring 21, so that it advances towards the first insulating member 224 in a symmetrical and complementary manner until the mating surfaces of the first insulating member 224 and the second insulating member 225 abut against each other, thereby realizing the assembly of the insulating member 22 and the stator ring 21. After assembly, the semi-open slots or flange structures located on the two insulating parts 22 respectively together form a clearance opening 222 for each tooth 211 to pass through. At the same time, after the two are connected, insulating protrusions 223 are also formed on both sides of the tooth 211. Therefore, it is not necessary to put the stator ring 21 into the injection molding equipment for injection molding. The assembly of the insulating part 22 and the stator ring 21 can be achieved by axial assembly.

[0034] In one embodiment, a guide groove 213 is provided between any two adjacent teeth 211. The guide groove 213 is opened on the outside of the stator body 212 and extends along the axial direction of the stator body 212. A first insert 2241 is provided on the inner side of the first insulating member 224, and a second insert 2251 is provided on the inner side of the second insulating member 225. In step S211, the first insert 2241 is inserted into the guide groove 213 from one end along the axial direction of the stator ring 21, so that the first insulating member 224 is assembled on the stator ring 21. In step S212, the second insert 2251 is inserted into the guide groove 213 from the other end along the axial direction of the stator ring 21, so that the second insulating member 225 is assembled on the stator ring 21.

[0035] In this embodiment, a guide groove 213 is machined between any two adjacent teeth 211 on the stator body 212. The guide groove 213 is formed on the outer peripheral surface of the stator body 212 and extends through it along the axial direction of the stator body 212. The guide groove 213 is used to provide guidance and positioning reference for the axial assembly of the first insulating member 224 and the second insulating member 225. At the same time, a first insert 2241 that cooperates with the guide groove 213 is provided at a corresponding position on the inner side of the first insulating member 224, and a second insert 2251 that cooperates with the guide groove 213 is provided at a corresponding position on the inner side of the second insulating member 225. The cross-sectional shape and size of the insert can form a sliding fit with the guide groove 213. In step S211, the first insulating member 224 slides its inner first insert 2241 from one end of the guide groove 213 along the axial direction and inserts it into the corresponding guide groove 213. The radial and circumferential limiting is achieved by the cooperation between the insert and the groove wall, thereby assembling the first insulating member 224 to the preset position of the stator ring 21. Subsequently, in step S212, the second insulating member 225 is assembled in the opposite direction to the assembly direction of the first insulating member 224. The second insert 2251 on its inner side slides axially from the other end of the guide groove 213 and is inserted into the same guide groove 213, causing the second insulating member 225 and the first insulating member 224 to move towards each other until they abut and mate in the guide groove 213. This arrangement ensures that the two insulating members 22 are aligned in the circumferential direction and prevents relative rotation. Furthermore, through the axial bidirectional insertion method, the insulating members 22 do not need to be assembled with the stator ring 21 by injection molding, allowing the first insulating member 224 and the second insulating member 225 to be detachably connected to the stator ring 21, thereby facilitating subsequent maintenance of the stator assembly 100.

[0036] In one embodiment, the stator ring 21 is configured as a single-piece molded component. In this embodiment, the stator ring 21 can be directly manufactured into a complete single component using processes such as powder metallurgy, precision casting, die forging, or one-time molding with high-performance composite materials, rather than being assembled from multiple parts through welding, riveting, or bolting. This eliminates any physical seams or mechanical connection interfaces in the stator ring 21, enhancing the overall mechanical strength and rigidity of the structure. It can better withstand periodic stresses and vibrations caused by electromagnetic forces and fundamentally eliminates the contact magnetic resistance and additional losses that may exist in traditional laminated or segmented structures. This provides a continuous, uniform, and low-loss flow path for magnetic flux, improving magnetic circuit continuity, structural coaxiality, and dimensional stability, ensuring a more stable fit between components. Simultaneously, the single-piece molding process reduces the number of parts, simplifies assembly processes, and improves motor assembly efficiency.

[0037] In one embodiment, the stator ring assembly 2 further includes a limiting block 214. Each tooth 211 has a limiting block 214 on its side away from the stator body 212, and the inner peripheral wall of the stator yoke 3 has a limiting groove 31 that mates with the limiting block 214. In step S3, the limiting block 214 is inserted into the limiting groove 31 along the axial direction of the stator yoke 3, so that the stator yoke 3 is assembled into the stator ring assembly 2. The stator ring assembly 2 has a protruding limiting block 214 on the outer side of the end of each tooth 211 away from the stator body 212. The limiting block 214 can be integrally formed with the tooth 211 or fixedly connected by a stable connection method. On the inner peripheral wall of the stator yoke 3 to be assembled, limiting grooves 31 are machined to match the number, position, and shape of the limiting blocks 214. In step S3, the stator yoke 3 is slid axially and fitted onto the stator ring assembly 2 with the installed insulator 22 and coil. The limiting blocks 214 at the ends of each tooth 211 are aligned and slid into the corresponding limiting grooves 31 on the inner wall of the stator yoke 3, thereby achieving circumferential and radial positioning of both components. The cooperation between the limiting blocks 214 and the limiting grooves 31 guides the assembly of the stator yoke 3 and the stator ring assembly 2, preventing relative rotation or radial offset between the stator yoke 3 and the stator ring assembly 2 during axial sliding assembly. This enhances the mechanical stability and positioning accuracy of the stator structure, thereby improving the mechanical stability of the motor, while achieving a detachable connection between the stator yoke 3 and the stator ring assembly 2.

[0038] See Figure 1 , Figure 4 In one embodiment, step S4 includes the following steps: providing a wire connector, connecting and fixing the wire connector to the stator ring assembly and / or stator yoke; and electrically connecting the wire connector to a portion of the conductive coils. In step S4, a dedicated wire connector 4 is first provided. The wire connector 4 can be a metal busbar, a pre-formed connecting piece, or an integrated terminal module, etc. The wire connector 4 is fixedly installed on a preset mounting position of the stator ring assembly 2 or stator yoke 3 to prevent the wire connector 4 from loosening, and to facilitate subsequent operation and maintenance. Subsequently, resistance welding, laser welding, ultrasonic welding, or mechanical crimping can be used to electrically connect the terminals on the wire connector 4 to the wire ends of a preset portion of the conductive coils 1. At this time, the wire connector 4 forms a common node or phase-to-phase bridging point for each phase winding, while the connection of the remaining conductive coils 1 is completed by their own wire ends crossing or directly paralleling, thereby enabling all conductive coils 1 to be connected in series or in parallel in the target manner to form an electrical circuit.

[0039] In this embodiment, the conductor connector 4 includes a first conductor connector 4 and a second conductor connector 4. The first conductor connector 4 is integrally formed with the insulating body 221. When manufacturing the insulating part 22, a groove for accommodating the first conductor connector 4 can be formed in the insulating part 22. During assembly, the first conductor connector 4 is embedded in the groove, and the connection terminal of the first conductor connector 4 extends out of the insulating body 221. This allows the first conductor connector 4 and the insulating body 221 to form an integral structure without affecting the normal operation of the connector, so that the insulating body 221 and the first conductor connector 4 can be replaced as a modular structure. The second conductor connector 4 is installed on the stator yoke 3 by adhesive or fasteners. When the internal space of the insulating body 221 is limited and there is no space to install the conductor connector 4, the second conductor connector 4 is installed on the stator yoke 3, thereby cooperating with the first conductor connector 4 to connect multiple conductors in an orderly manner according to a preset pattern to form a stator winding that meets the preset requirements.

[0040] In one embodiment, in step S42, the wire connector 4 and the conductive coil 1 are connected by welding. In step S42, the electrical connection between the wire connector 4 and the conductive coil 1 is achieved by welding. Local heating melts and fuses the metal material at the connection point, resulting in higher mechanical strength at the wire joint, lower contact resistance, and higher resistance to vibration fatigue.

[0041] In one embodiment, the stator yoke 3 is configured as a single molded component. The stator yoke 3 can be directly manufactured into a complete single component using processes such as powder metallurgy, precision casting, die forging, or one-time molding of high-performance composite materials, rather than being assembled from multiple parts by welding, riveting, or bolting. This eliminates any physical seams or mechanical connection interfaces in the stator yoke 3, enhancing the overall mechanical strength and rigidity of the structure. Before assembly, the stator ring 21 and stator yoke 3 can also undergo electrophoretic processing. The entire stator ring 21 or stator yoke 3 is immersed in a dedicated electrophoretic paint tank. Under the action of an electric field, charged epoxy resin or acrylic resin paint particles migrate directionally and are uniformly deposited on all metal surfaces, including the complex gaps between teeth 211, grooves in the connecting parts, and other corners, thereby forming a dense, firmly adhered, and uniformly thick base coating, providing excellent corrosion and rust protection for the stator ring 21 and stator yoke 3.

[0042] The above description is merely an exemplary embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention specification and drawings under the technical concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A manufacturing process for a stator assembly, characterized in that, The manufacturing process of the stator assembly includes the following steps: S1. Provide multiple coil blanks, and wind each coil blank into a conductive coil according to a preset method; S2. A stator ring assembly is provided, the stator ring assembly having a plurality of teeth spaced apart in a circumferential direction, and a plurality of conductive coils are mounted one-to-one on the plurality of teeth; S3. A stator yoke is provided, the stator yoke is arranged in a ring shape, the stator yoke is arranged around the periphery of the stator ring assembly, and the stator yoke is detachably connected and fixed to the tooth portion; S4. Connect multiple conductive coils electrically in a preset manner so that the multiple conductive coils are connected in a preset manner.

2. The manufacturing process of the stator assembly as described in claim 1, characterized in that, In step S1, the coil blank is a flat wire, and the conductive coil is a flat wire coil.

3. The manufacturing process of the stator assembly as described in claim 1, characterized in that, The stator ring assembly includes a stator ring and an insulating component. The stator ring includes a stator body arranged in a ring shape and a plurality of teeth spaced circumferentially on the outer wall of the stator body. The insulating component includes an insulating body arranged in a ring shape and a plurality of clearance openings spaced circumferentially on the insulating body. Each clearance opening has an insulating protrusion on both sides along the axial direction of the stator ring. Step S2 includes the following steps: S21. Assemble the insulating member with the stator ring so that the insulating body of the insulating member surrounds the outer peripheral surface of the stator body, and pass the teeth through the clearance opening and position them between the two opposing insulating protrusions. S22. Install a plurality of the conductive coils one-to-one on a plurality of the teeth and cover the insulating protrusions on both sides of the teeth.

4. The manufacturing process of the stator assembly as described in claim 3, characterized in that, The insulating element includes a first insulating element and a second insulating element disposed opposite to each other along the axial direction of the stator ring; Step S21 includes the following steps: S211. Assemble the first insulating member with the first end of the stator ring; S212. Assemble the second insulating member to the second end of the stator ring so that the second insulating member is mated with the first insulating member and forms the clearance opening for the teeth to pass through.

5. The manufacturing process of the stator assembly as described in claim 4, characterized in that, A guide groove is provided between any two adjacent teeth. The guide groove is opened on the outside of the stator body and extends along the axial direction of the stator body. A first insert is provided on the inside of the first insulating member and a second insert is provided on the inside of the second insulating member. In step S211, the first insert is inserted into the guide groove from one end along the axial direction of the stator ring, so that the first insulating member is assembled onto the stator ring; In step S212, the second insert is inserted into the guide groove from the other end of the guide groove along the axial direction of the stator ring, so that the second insulating member is assembled onto the stator ring.

6. The manufacturing process of the stator assembly as described in claim 3, characterized in that, The stator ring is configured as a one-piece molded part.

7. The manufacturing process of the stator assembly as described in claim 1, characterized in that, The stator ring assembly further includes a limiting block, and each of the teeth is provided with the limiting block on the side away from the stator body. The inner peripheral wall of the stator yoke is provided with a limiting groove that cooperates with the limiting block. In step S3, the limiting block is inserted into the limiting groove along the axial direction of the stator yoke so that the stator yoke is assembled into the stator ring assembly.

8. The manufacturing process of the stator assembly as described in claim 1, characterized in that, Step S4 includes the following steps: S41. Provide a wire connector to connect and fix the wire connector to the stator ring assembly and / or the stator yoke; S42. Electrically connect the wire connector to a portion of the conductive coil.

9. The manufacturing process of the stator assembly as described in claim 8, characterized in that, In step S42, the wire connector is connected to the conductive coil by welding.

10. The manufacturing process of the stator assembly as described in any one of claims 1 to 9, characterized in that, The stator yoke is configured as a single molded part.

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